TM-9-2320-280-20-3 HMMWV Unit Maintnance Vol 3

ARMY TM 9-2320-280-20-3
AIR FORCE TO 36A12-1A-2092-1-3

MARINE CORPS TM 2320-20/7C
Volume No. 3 (SUPERSEDES TM 9-2320-280-20-3, 1 NOVEMBER 1993)
TECHNICAL MANUAL
UNIT MAINTENANCE
TRUCK, UTILITY: CARGO/TROOP CARRIER, 1-1/4 TON, 4X4, M998
(2320-01-107-7155) (EIC: BBD); M998A1 (2320-01-371-9577) (EIC: BBN);
TRUCK, UTILITY: CARGO/TROOP CARRIER, 1-1/4 TON, 4X4, W/WINCH,
M1038 (2320-01-107-7156) (EIC: BBE); M1038A1 (2320-01-371-9578) (EIC: BBP);
TRUCK, UTILITY: HEAVY VARIANT, 4X4, M1097 (2320-01-346-9317) (EIC: BBM); BODY AND ACCESSORIES 10-1
M1097A1 (2320-01-371-9583) (EIC: BBU); M1097A2 (2320-01-380-8604) (EIC: BB6); MAINTENANCE
M1123 (2320-01-455-9593) (EIC: B6G);
TRUCK, UTILITY: TOW CARRIER, ARMORED, 1-1/4 TON, 4X4,
M966 (2320-01-107-7153) (EIC: BBC); M966A1 (2320-01-372-3932) (EIC: BBX);
M1121 (2320-01-456-1282) (EIC: B6H);
TRUCK, UTILITY: TOW CARRIER, ARMORED, 1-1/4 TON, 4X4, W/WINCH,
M1036 (2320-01-107-7154) (EIC: BBH);
SPECIAL PURPOSE
TRUCK, UTILITY: TOW CARRIER, W/SUPPLEMENTAL ARMOR, 1-1/4 TON, 4X4, 11-1
BODIES MAINTENANCE
M1045 (2320-01-146-7191); M1045A1 (2320-01-371-9580) (EIC: BBR);
M1045A2 (2320-01-380-8229) (EIC: BB5);
TRUCK, UTILITY: TOW CARRIER, W/SUPPLEMENTAL ARMOR, 1-1/4 TON, 4X4, W/WINCH,
M1046 (2320-01-146-7188); M1046A1 (2320-01-371-9582) (EIC: BBT);
TRUCK, UTILITY: ARMAMENT CARRIER, ARMORED, 1-1/4 TON, 4X4, M1025
(2320-01-128-9551) (EIC: BBF); M1025A1 (2320-01-371-9584) (EIC: BBV);
M1025A2 (2320-01-380-8233) (EIC: BB3); SPECIAL PURPOSE KITS 12-1
MAINTENANCE
TRUCK, UTILITY: ARMAMENT CARRIER, ARMORED, 1-1/4 TON, 4X4, W/WINCH,
M1026 (2320-01-128-9552) (EIC: BBG); M1026A1 (2320-01-371-9579) (EIC: BBQ);
TRUCK, UTILITY: ARMAMENT CARRIER, W/SUPPLEMENTAL ARMOR, 1-1/4 TON, 4X4,
M1043 (2320-01-146-7190); M1043A1 (2320-01-372-3933) (EIC: BBY);
M1043A2 (2320-01-380-8213) (EIC: BB4);
W/WINCH, M1044 (2320-01-146-7189); M1044A1 (2320-01-371-9581) (EIC: BBS); PREPARATION FOR 13-1
TRUCK, UTILITY: S250 SHELTER CARRIER, 4X4, M1037 (2320-01-146-7193) (EIC: BBK); STORAGE OR SHIPMENT
TRUCK, UTILITY: S250 SHELTER CARRIER, 4X4, W/WINCH, M1042 (2320-01-146-7187);

TRUCK, AMBULANCE, 2-LITTER, ARMORED, 4X4, M996 (2310-01-111-2275)
(EIC: BBB); M996A1 (2310-01-372-3935) (EIC: BB2);
TRUCK, AMBULANCE, 4-LITTER, ARMORED, 4X4, M997 (2310-01-111-2274) (EIC: BBA);
M997A1 (2310-01-372-3934) (EIC: BBZ); M997A2 (2310-01-380-8225) (EIC: BB8);
TRUCK, AMBULANCE, 2-LITTER, SOFT TOP, 4X4, M1035 (2310-01-146-7194);
M1035A1 (2310-01-371-9585) (EIC: BBW); M1035A2 (2310-01-380-8290) (EIC: BB9).
Approved for public release; distribution is unlimited.
HEADQUARTERS, DEPARTMENTS OF THE ARMY,

THE AIR FORCE, AND MARINE CORPS
JANUARY 1996
PIN: 068171-001
TM 9-2320-280-20-3
WARNING
EXHAUST GASES CAN KILL
Brain damage or death can result from heavy exposure. Precautions must be followed to ensure crew safety
when the personnel heater, main or auxiliary engine of any vehicle is operated for any purpose.
1. Do not operate your vehicle engine in enclosed areas.
2. Do not idle vehicle engine with vehicle windows closed.
3. Be alert at all times for exhaust odors.
4. Be alert for exhaust poisoning symptoms. they are:
● Headache
@ Dizziness
● Sleepiness
● Loss of muscular control
5. If you see another person with exhaust poisoning symptoms:

● Remove person from area
“ Expose to open air
● Keep person warm
● Do not permit physical exercise
● Administer artificial respiration, if necessary*
● Notify a medic
*For artificial respiration, refer to FM 21-11.

6. BE AWARE, the field protective mask for nuclear, biological or chemical (NBC) protection will not
protect you from carbon monoxide poisoning.
THE BEST DEFENSE AGAINST EXHAUST POISONING IS ADEQUATE VENTILATION.
a
TM 9-2320-280-20-3
WARNING SUMMARY
● Hood must be supported during removal and installation and hood prop rod and bracket replacement.
Failure to support hood may cause injury to personnel or damage to equipment.
c Diesel fuel is highly flammable. Do not perform this procedure near fire, flames, or sparks. Severe injury
or death will result.
Q Do not touch hot exhaust system components with bare hands. Severe injury will result.
. Windshield must be supported during removal and installation. Failure to support windshield may cause
injury to personnel or damage to equipment.
● Winch must be supported during removal and installation. Failure to support winch may cause severe
c Gloves must be worn whenever handling winch cable. Severe injury may result.
● Opening one end of cargo door before ensuring opposite end is securely closed will cause both ends to open
simultaneously, resulting in injury to personnel or damage to equipment.
● Rear steps must be raised before disconnecting retractor lever from rear steps. Failure to do this may
cause injury to personnel and damage to equipment.
● NBC contaminated filters must be handled and disposed of only by authorized and trained personnel. The
unit commander or senior officer in charge of maintenance personnel must ensure that prescribed
protective clothing (FM 3-4) is used, and prescribed safety measures and decontamination procedures
(FM 3-5) are followed. The local unit SOP is responsible for final disposal of contaminated air filters.
Failure to do this may cause severe injury to personnel.
● Seatbelts are to be replaced as a set. Failure to do this may cause injury to personnel or damage to
equipment.
@ Use eyeshields and gloves when removing and installing windshield. Glass could shatter causing injury.
● One assistant will be required to hold the cargo door open when either one or both gas springs are being
removed and installed. Failure to do so may result in injury to personnel or damage to equipment.
● Direct all personnel to stand clear during any hoisting operations. A heavy, swinging load can be
extremely dangerous. Failure to do so may cause injury to personnel or damage to equipment.
b
TM 9-2320-280-20-3
LIST OF EFFECTIVE PA G E S
NOTE: The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page.
Dates of issue for original and

changed pages of volume 3 are:
Original........ 0 ......31 January 1996
Change ........ 1 ..........30 June 1999
TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 827. CONSISTING OF THE FOLLOWING:
Page No. . . . . . . . .*Change No. Page No. . . . . . . . .*Change No. Page No. . . . . . . . .*Change No.
VOLUME 3 10-147 - 10-149 . . . . . . . . . . . . .0 11-69 - 11-70 . . . . . . . . . . . . . . .1
a - b . . . . . . . . . . . . . . . . . . . . . .0 10-150 . . . . . . . . . . . . . . . . . . . .1 11-71 - 11-74 . . . . . . . . . . . . . . .0
A - B . . . . . . . . . . . . . . . . . . . . .1 10-151 . . . . . . . . . . . . . . . . . . . .0 11-75 - 11-76 . . . . . . . . . . . . . . .1
i - ii . . . . . . . . . . . . . . . . . . . . . .1 10-152 - 10-154 . . . . . . . . . . . . .1 11-77 . . . . . . . . . . . . . . . . . . . . .0
10-1 - 10-2 . . . . . . . . . . . . . . . . .1 10-154.1 - 10-154.2 Added . . . .1 11-78 - 11-82 . . . . . . . . . . . . . . .1
10-3 - 10-7 . . . . . . . . . . . . . . . . .0 10-155 - 10-156 . . . . . . . . . . . . .1 11-83 - 11-131 . . . . . . . . . . . . . .0
10-8 - 10-9 . . . . . . . . . . . . . . . . .1 10-157 - 10-159 . . . . . . . . . . . . .0 11-132 - 11-134 . . . . . . . . . . . . .1
10-10 - 10-14 . . . . . . . . . . . . . . .0 10-160 - 10-161 . . . . . . . . . . . . .1 11-134.1 Added . . . . . . . . . . . . .1
10-14.1 Added . . . . . . . . . . . . . .1 10-162 Blank . . . . . . . . . . . . . .1 11-134.2 Blank . . . . . . . . . . . . .1
10-14.2 Blank . . . . . . . . . . . . . .1 10-163 - 10-164 . . . . . . . . . . . . .1 11-135 - 11-156 . . . . . . . . . . . . .0
10-15 . . . . . . . . . . . . . . . . . . . . .0 10-164.1 - 10-164.6 Added . . . .1 11-156.1 - 11-156.6 Added . . . .1
10-16 . . . . . . . . . . . . . . . . . . . . .1 10-165 - 10-166 . . . . . . . . . . . . .1 11-157 - 11-160 . . . . . . . . . . . . .1
10-17 - 10-33 . . . . . . . . . . . . . . .0 10-166.1 Added . . . . . . . . . . . . .1 11-161 - 11-172 . . . . . . . . . . . . .0
10-34 . . . . . . . . . . . . . . . . . . . . .1 10-166.2 Blank . . . . . . . . . . . . .1 11-173 - 11-174 . . . . . . . . . . . . .1
10-35 - 10-36 . . . . . . . . . . . . . . .0 10-167 . . . . . . . . . . . . . . . . . . . .0 11-175 - 11-201 . . . . . . . . . . . . .0
10-37 - 10-38 . . . . . . . . . . . . . . .1 10-168 . . . . . . . . . . . . . . . . . . . .1 11-202 . . . . . . . . . . . . . . . . . . . .1
10-39 - 10-45 . . . . . . . . . . . . . . .0 10-169 - 10-171 . . . . . . . . . . . . .0 11-202.1 - 11-202.2 Added . . . .1
10-46 . . . . . . . . . . . . . . . . . . . . .1 10-172 . . . . . . . . . . . . . . . . . . . .1 11-203 - 11-205 . . . . . . . . . . . . .1
10-47 - 10-56 . . . . . . . . . . . . . . .0 10-172.1 - 10-172.4 Added . . . .1 11-206 - 11-212 . . . . . . . . . . . . .0
10-56.1 - 10-56.2 Added . . . . . .1 10-173 . . . . . . . . . . . . . . . . . . . .1 11-212.1 - 11-212.2 Added . . . .1
10-57 . . . . . . . . . . . . . . . . . . . . .1 10-174 . . . . . . . . . . . . . . . . . . . .0 11-213 . . . . . . . . . . . . . . . . . . . .1
10-58 - 10-80 . . . . . . . . . . . . . . .0 10-175 - 10-176 . . . . . . . . . . . . .1 11-214 - 11-262 . . . . . . . . . . . . .0
10-80.1 - 10-80.2 Added . . . . . .1 10-176.1 - 10-176.2 Added . . . .1 11-262.1 Added . . . . . . . . . . . . .1
10-81 . . . . . . . . . . . . . . . . . . . . .1 10-177 - 10-178 . . . . . . . . . . . . .0 11-262.2 Blank . . . . . . . . . . . . .1
10-82 . . . . . . . . . . . . . . . . . . . . .0 10-179 . . . . . . . . . . . . . . . . . . . .1 11-263 - 11-306 . . . . . . . . . . . . .0
10-82.1 - 10-82.2 Added . . . . . .1 10-180 - 10-186 . . . . . . . . . . . . .0 11-307 . . . . . . . . . . . . . . . . . . . .1
10-83 . . . . . . . . . . . . . . . . . . . . .1 10-186.1 - 10-186.4 . . . . . . . . . .1 11-308 - 11-325 . . . . . . . . . . . . .0
10-84 - 10-92 . . . . . . . . . . . . . . .0 10-187 . . . . . . . . . . . . . . . . . . . .1 11-326 Blank . . . . . . . . . . . . . .0
10-93 . . . . . . . . . . . . . . . . . . . . .1 10-188 - 10-190 . . . . . . . . . . . . .0 12-1 . . . . . . . . . . . . . . . . . . . . . .1
10-94 - 10-110 . . . . . . . . . . . . . .0 10-190.1 - 10-190.2 . . . . . . . . . .1 12-2 - 12-6 . . . . . . . . . . . . . . . . .0
10-111 - 10-112 . . . . . . . . . . . . .1 10-191 Blank . . . . . . . . . . . . . .1 12-7 - 12-8 . . . . . . . . . . . . . . . . .1
10-113 - 10-114 . . . . . . . . . . . . .0 10-192 . . . . . . . . . . . . . . . . . . . .0 12-9 - 12-22 . . . . . . . . . . . . . . . .0
10-114.1 Added . . . . . . . . . . . . .1 10-193 - 10-195 . . . . . . . . . . . . .1 12-23 - 12-24 . . . . . . . . . . . . . . .1
10-114.2 Blank . . . . . . . . . . . . .1 10-196 Blank . . . . . . . . . . . . . .1 12-25 . . . . . . . . . . . . . . . . . . . . .0
10-115 . . . . . . . . . . . . . . . . . . . .1 11-1 . . . . . . . . . . . . . . . . . . . . . .0 12-26 . . . . . . . . . . . . . . . . . . . . .1
10-116 - 10-123 . . . . . . . . . . . . .0 11-2 . . . . . . . . . . . . . . . . . . . . . .1 12-27 . . . . . . . . . . . . . . . . . . . . .0
10-124 . . . . . . . . . . . . . . . . . . . .1 11-3 . . . . . . . . . . . . . . . . . . . . . .0 12-28 . . . . . . . . . . . . . . . . . . . . .1
10-125 . . . . . . . . . . . . . . . . . . . .0 11-4 . . . . . . . . . . . . . . . . . . . . . .1 12-28.1 - 12-28.2 Added . . . . . .1
10-126 . . . . . . . . . . . . . . . . . . . .1 11-5 - 11-48 . . . . . . . . . . . . . . . .0 12-29 . . . . . . . . . . . . . . . . . . . . .1
10-127 . . . . . . . . . . . . . . . . . . . .0 11-48.1 Added . . . . . . . . . . . . . .1 12-30 - 12-31 . . . . . . . . . . . . . . .0
10-128 . . . . . . . . . . . . . . . . . . . .1 11-48.2 Blank . . . . . . . . . . . . . .1 12-32 - 12-34 . . . . . . . . . . . . . . .1
10-129 - 10-145 . . . . . . . . . . . . .0 11-49 - 11-50 . . . . . . . . . . . . . . .1 12-34.1 - 12-34.8 Added . . . . . .1
10-146 . . . . . . . . . . . . . . . . . . . .1 11-51 - 11-68 . . . . . . . . . . . . . . .0 12-35 - 12-36 . . . . . . . . . . . . . . .1
*Zero in this column indicates original page.
Change 1 A
TM 9-2320-280-20-3
LIST OF EFFECTIVE PAGES (Cont’d)
Page No. . . . . . . . .*Change No. Page No. . . . . . . . .*Change No. Page No. . . . . . . . .*Change No.
12-37 . . . . . . . . . . . . . . . . . . . . .0 12-223 - 12-281 . . . . . . . . . . . . .0 F-1 . . . . . . . . . . . . . . . . . . . . . . 1
12-38 - 12-39 . . . . . . . . . . . . . . .1 12-282 . . . . . . . . . . . . . . . . . . . .1 F-2 - F-12 . . . . . . . . . . . . . . . . .0
12-40 - 12-56 . . . . . . . . . . . . . . .0 12-283 - 12-294 . . . . . . . . . . . . .0 G-1 . . . . . . . . . . . . . . . . . . . . . .0
12-57 . . . . . . . . . . . . . . . . . . . . .1 12-295 - 12-317 . . . . . . . . . . . . .1 G-2 - G-8 . . . . . . . . . . . . . . . . . .1
12-58 - 12-62 . . . . . . . . . . . . . . .0 12-318 Blank . . . . . . . . . . . . . .1 G-9 Added . . . . . . . . . . . . . . . . .1
12-62.1 - 12-62.2 Added . . . . . .1 A-1 . . . . . . . . . . . . . . . . . . . . . . .0 G-10 Blank . . . . . . . . . . . . . . . .1
12-63 . . . . . . . . . . . . . . . . . . . . .1 A-2 . . . . . . . . . . . . . . . . . . . . . . .1 Index 1-35 . . . . . . . . . . . . . . . . .1
12-64 - 12-68 . . . . . . . . . . . . . . .0 B-1 - B-3 . . . . . . . . . . . . . . . . . .0 Index 36 Blank . . . . . . . . . . . . .1
12-69 . . . . . . . . . . . . . . . . . . . . .1 B-4 - B-27 . . . . . . . . . . . . . . . . .1 FP-1 . . . . . . . . . . . . . . . . . . . . .0
12-70 . . . . . . . . . . . . . . . . . . . . .0 B-28 Blank . . . . . . . . . . . . . . . .0 FP-2 Blank . . . . . . . . . . . . . . . .0
12-70.1 - 12-70.4 Added . . . . . .1 C-1 . . . . . . . . . . . . . . . . . . . . . . .0 FP-3 . . . . . . . . . . . . . . . . . . . . .0
12-71 - 12-72 . . . . . . . . . . . . . . .1 C-2 - C-7 . . . . . . . . . . . . . . . . . .1 FP-4 Blank . . . . . . . . . . . . . . . .0
12-72.1 Added . . . . . . . . . . . . . .1 C-8 Blank . . . . . . . . . . . . . . . . .0 FP-5 . . . . . . . . . . . . . . . . . . . . .0
12-72.2 Blank . . . . . . . . . . . . . .1 D-1 - D-2 . . . . . . . . . . . . . . . . . .1 FP-6 Blank . . . . . . . . . . . . . . . .0
12-73 - 12-109 . . . . . . . . . . . . . .0 D-3 - D-9 . . . . . . . . . . . . . . . . . .0 FP-7 . . . . . . . . . . . . . . . . . . . . .0
12-110 - 12-111 . . . . . . . . . . . . .1 D-10 . . . . . . . . . . . . . . . . . . . . .1 FP-8 Blank . . . . . . . . . . . . . . . .0
12-112 - 12-200 . . . . . . . . . . . . .0 D-11 - D-46 . . . . . . . . . . . . . . . .0 FP-9 . . . . . . . . . . . . . . . . . . . . .0
12-201 - 12-202 . . . . . . . . . . . . .1 D-46.1 - D-46.2 Added . . . . . . .1 FP-10 Blank . . . . . . . . . . . . . . .0
12-202.1 - 12-202.2 Added . . . .1 D-47 - D-48 . . . . . . . . . . . . . . . .1 FP-11 . . . . . . . . . . . . . . . . . . . . .0
12-203 - 12-204 . . . . . . . . . . . . .1 D-49 - D-64 . . . . . . . . . . . . . . . .0 FP-12 Blank . . . . . . . . . . . . . . .0
12-204.1 - 12-204.4 Added . . . .1 D-65 - D-66 . . . . . . . . . . . . . . . .1 FP-13 . . . . . . . . . . . . . . . . . . . .0
12-205 . . . . . . . . . . . . . . . . . . . .1 D-67 - D-70 . . . . . . . . . . . . . . . .0 FP-14 Blank . . . . . . . . . . . . . . .0
12-206 - 12-220 . . . . . . . . . . . . .0 D-71 . . . . . . . . . . . . . . . . . . . . .1 FP-15 . . . . . . . . . . . . . . . . . . . .0
12-221 - 12-222 . . . . . . . . . . . . .1 D-72 - D-77 . . . . . . . . . . . . . . . .0 FP-16 Blank . . . . . . . . . . . . . . .0
12-222.1 Added . . . . . . . . . . . . .1 D-78 - D-116 . . . . . . . . . . . . . . .1 FP-17 . . . . . . . . . . . . . . . . . . . .0
12-222.2 Blank . . . . . . . . . . . . .1 E-1 - E-4 . . . . . . . . . . . . . . . . . .0 FP-18 Blank . . . . . . . . . . . . . . .0
*Zero in this column indicates original page.
B Change 1
ARMY TM 9-2320-280-20-3
CHANGE HEADQUARTERS,
DEPARTMENTS OF THE ARMY,
NO. 1 THE AIR FORCE, AND MARINE CORPS
WASHINGTON, D.C., 30 JUNE 1999
TECHNICAL MANUAL
VOLUME 3 OF 3
UNIT MAINTENANCE
TRUCK, UTILITY: CARGO/TROOP CARRIER, 1-1/4 TON, 4X4,
M998 (2320-01-107-7155) (EIC: BBD); M998A1 (2320-01-371-9577) (EIC: BBN);
TRUCK, UTILITY: CARGO/TROOP CARRIER, 1-1/4 TON, 4X4, W/WINCH,
M1038 (2320-01-107-7156) (EIC: BBE); M1038A1 (2320-01-371-9578) (EIC: BBP);
TRUCK, UTILITY: HEAVY VARIANT, 4X4, M1097 (2320-01-346-9317) (EIC: BBM);
M1097A1 (2320-01-371-9583) (EIC: BBU); M1097A2 (2320-01-380-8604) (EIC: BB6); M1123 (2320-01-455-9593) (EIC: B6G);
TRUCK, UTILITY: TOW CARRIER, ARMORED, 1-1/4 TON, 4X4,
M966 (2320-01-107-7153) (EIC: BBC); M966A1 (2320-01-372-3932) (EIC: BBX); M1121 (2320-01-456-1282) (EIC: B6H);
TRUCK, UTILITY: TOW CARRIER, ARMORED, 1-1/4 TON, 4X4, W/WINCH,
M1036 (2320-01-107-7154) (EIC: BBH);
TRUCK, UTILITY: TOW CARRIER, W/SUPPLEMENTAL ARMOR, 1-1/4 TON, 4X4,
M1045 (2320-01-146-7191); M1045A1 (2320-01-371-9580) (EIC: BBR); M1045A2 (2320-01-380-8229) (EIC: BB5);
TRUCK, UTILITY: TOW CARRIER, W/SUPPLEMENTAL ARMOR, 1-1/4 TON, 4X4, W/WINCH,
M1046 (2320-01-146-7188); M1046A1 (2320-01-371-9582) (EIC: BBT);
TRUCK, UTILITY: ARMAMENT CARRIER, ARMORED, 1-1/4 TON, 4X4,
M1025 (2320-01-128-9551) (EIC: BBF); M1025A1 (2320-01-371-9584) (EIC: BBV); M1025A2 (2320-01-380-8233) (EIC: BB3);
TRUCK, UTILITY: ARMAMENT CARRIER, ARMORED, 1-1/4 TON, 4X4, W/WINCH,
M1026 (2320-01-128-9552) (EIC: BBG); M1026A1 (2320-01-371-9579) (EIC: BBQ);
M1043 (2320-01-146-7190); M1043A1 (2320-01-372-3933) (EIC: BBY); M1043A2 (2320-01-380-8213) (EIC: BB4);
TRUCK, UTILITY: ARMAMENT CARRIER, W/SUPPLEMENTAL ARMOR, 1-1/4 TON, 4X4, W/WINCH,
M1044 (2320-01-146-7189); M1044A1 (2320-01-371-9581) (EIC: BBS);
TRUCK, UTILITY: S250 SHELTER CARRIER, 4X4, M1037 (2320-01-146-7193) (EIC: BBK);
TRUCK, AMBULANCE, 2-LITTER, ARMORED, 4X4, M996 (2310-01-111-2275) (EIC: BBB); M996A1 (2310-01-372-3935) (EIC: BB2);
TRUCK, AMBULANCE, 2-LITTER, SOFT TOP, 4X4,
M1035 (2310-01-146-7194); M1035A1 (2310-01-371-9585) (EIC: BBW); M1035A2 (2310-01-380-8290) (EIC: BB9).
TM 9-2320-280-20-3, 31 January 1996, is changed as follows:

1. Two new models have been added to the front cover. The new cover, located at the end of the change
package, replaces the existing cover.
2. Remove old pages and insert new pages as indicated below.
3. New or changed material is indicated by a vertical bar in the margin of the page.
Remove pages Insert pages
None A and B (after Warning d blank)
i and ii i and ii
10-1 and 10-2 10-1 and 10-2
10-7 through 10-10 10-7 through 10-10
None 10-14.1/(10-14.2 blank)
10-15 and 10-16 10-15 and 10-16
10-33 and 10-34 10-33 and 10-34
Remove pages Insert pages
10-37 and 10-38 10-37 and 10-38

10-45 and 10-46 10-45 and 10-46
10-57 and 10-58 10-56.1 through 10-58
10-81 through 10-84 10-80.1 through 10-84
10-93 and 10-94 10-93 and 10-94
10-111 and 10-112 10-111 and 10-112
10-115 and 10-116 10-114.1/(10-114.2 blank) through 10-116
10-123 through 10-128 10-123 through 10-128
10-145 and 10-146 10-145 and 10-146
10-149 through 10-156 10-149 through 10-156
10-159 through 10-168 10-159 through 10-168
10-171 through 10-176 10-171 through 10-176.2
10-179 and 10-180 10-179 and 10-180
10-187 and 10-188 10-186.1 through 10-188
10-191 through 10-193/(10-194 blank) 10-190.1 through 10-195/(10-196 blank)
11-1 through 11-4 11-1 through 11-4
11-49 and 11-50 11-48.1/(11-48.2 blank) through 11-50
11-69 and 11-70 11-69 and 11-70
11-75 through 11-82 11-75 through 11-82
11-131 through 11-134 11-131 through 11-134.1/(11-134.2 blank)
11-157 through 11-160 11-156.1 through 11-160
11-173 and 11-174 11-173 and 11-174
11-201 through 11-206 11-201 through 11-206
11-213 and 11-214 11-212.1 through 11-214
None 11-262.1/(11-262.2 blank)
11-307 and 11-308 11-307 and 11-308
12-1 and 12-2 12-1 and 12-2
12-7 and 12-8 12-7 and 12-8
12-23 through 12-40 12-23 through 12-40
12-57 and 12-58 12-57 and 12-58
12-63 and 12-64 12-62.1 through 12-64
12-69 through 12-72 12-69 through12-72.1/(12-72.2 blank)
12-109 through 12-112 12-109 through 12-112
12-201 and 12-206 12-201 through 12-206
12-221 and 12-222 12-221 through 12-222.1/(12-222.2 blank)
12-281 and 12-282 12-281 and 12-282
12-295/(12-296 blank) 12-295 through 12-317/(12-318 blank)
A-1 and A-2 A-1 and A-2
B-3 through B-27/(B-28 blank) B-3 through B-27/(B-28 blank)
C-1 through C-7/(C-8 blank) C-1 through C-7/(C-8 blank)
D-1 and D-2 D-1 and D-2
D-9 and D-10 D-9 and D-10
D-47 and D-48 D-46.1 through D-48
D-65 and D-66 D-65 and D-66
D-71 and D-72 D-71 and D-72
D-77 through D-106 D-77 through D-116
F-1 and F-2 F-1 and F-2
G-1 through G-8 G-1 through G-9/ (G-10 blank)
Index 1 through Index 33 Index 1 through Index 35/(Index 36 blank)
cover cover
4. File this change sheet in front of the publication for reference purposes.
By Order of the Secretary of the Army:
ERIC K. SHINSEKI
General, United States Army
Chief of Staff
Official:
JOEL B. HUDSON
Administrative Assistant to the
Secretary of the Army
05692
By Order of the Secretary of the Air Force:
RONALD R. FOGLEMAN
General, United States Air Force
Chief of Staff
Official:
H E N RY VICCELLIO, JR.
General, United States Air Force
C o m m a n d e r, Air Force Materiel Command
By Order of the Marine Corps:
D.R. BLOOMER
Colonel, USMC
Director, Program Support
Marine Corps Systems Command
Distribution:
To be distributed in accordance with the initial distribution number (IDN) 380900, requirements for
TM 9-2320-280-20-3.
*ARMY TM 9-2320-280-20-3
TECHNICAL MANUAL HEADQUARTERS,
NO. 9-2320-280-20-3 DEPARTMENTS OF THE ARMY,
NO. 2320-20/7C THE AIR FORCE, AND MARINE CORPS
WASHINGTON, D.C., 31 JANUARY 1996
TECHNICAL ORDER
NO. 36A12-1A-2092-1-3
TECHNICAL MANUAL
VOLUME 3 OF 3
UNIT MAINTENANCE
TRUCK, UTILITY: CARGO/TROOP CARRIER, 1-1/4 TON, 4X4, M998 (2320-01-107-7155) (EIC: BBD);
M998A1 (2320-01-371-9577) (EIC: BBN);
TRUCK, UTILITY: CARGO/TROOP CARRIER, 1-1/4 TON, 4X4, W/WINCH, M1038 (2320-01-107-7156) (EIC: BBE);
M1038A1 (2320-01-371-9578) (EIC: BBP);
TRUCK, UTILITY: HEAVY VARIANT, 4X4, M1097 (2320-01-346-9317) (EIC: BBM); M1097A1 (2320-01-371-9583) (EIC: BBU);
M1097A2 (2320-01-380-8604) (EIC: BB6); M1123 (2320-01-455-9593) (EIC: B6G);
TRUCK, UTILITY: TOW CARRIER, ARMORED, 1-1/4 TON, 4X4, M966 (2320-01-107-7153) (EIC: BBC);
M966A1 (2320-01-372-3932) (EIC: BBX); M1121 (2320-01-456-1282) (EIC: B6H);
TRUCK, UTILITY: TOW CARRIER, ARMORED, 1-1/4 TON, 4X4, W/WINCH, M1036 (2320-01-107-7154) (EIC: BBH);
TRUCK, UTILITY: TOW CARRIER, W/SUPPLEMENTAL ARMOR, 1-1/4 TON, 4X4,
M1045 (2320-01-146-7191); M1045A1 (2320-01-371-9580) (EIC: BBR); M1045A2 (2320-01-380-8229) (EIC: BB5);
TRUCK, UTILITY: TOW CARRIER, W/SUPPLEMENTAL ARMOR, 1-1/4 TON, 4X4, W/WINCH, M1046 (2320-01-146-7188);
M1046A1 (2320-01-371-9582) (EIC: BBT);
TRUCK, UTILITY: ARMAMENT CARRIER, ARMORED, 1-1/4 TON, 4X4, M1025 (2320-01-128-9551) (EIC: BBF);
M1025A1 (2320-01-371-9584) (EIC: BBV); M1025A2 (2320-01-380-8233) (EIC: BB3);
TRUCK, UTILITY: ARMAMENT CARRIER, ARMORED, 1-1/4 TON, 4X4, W/WINCH, M1026 (2320-01-128-9552) (EIC: BBG);
M1026A1 (2320-01-371-9579) (EIC: BBQ);
TRUCK, UTILITY: ARMAMENT CARRIER, W/SUPPLEMENTAL ARMOR, 1-1/4 TON, 4X4, M1043 (2320-01-146-7190);
M1043A1 (2320-01-372-3933); M1043A2 (2320-01-380-8213) (EIC: BB4);
TRUCK, UTILITY: ARMAMENT CARRIER, W/SUPPLEMENTAL ARMOR, 1-1/4 TON, 4X4, W/WINCH, M1044 (2320-01-146-7189);
M1044A1 (2320-01-371-9581);
TRUCK, UTILITY: S250 SHELTER CARRIER, 4X4, M1037 (2320-01-146-7193) (EIC: BBK);
TRUCK, AMBULANCE, 2-LITTER, ARMORED, 4X4, M996 (2310-01-111-2275)
(EIC: BBB); M996A1 (2310-01-372-3935) (EIC: BB2);
TRUCK, AMBULANCE, 2-LITTER, SOFT TOP, 4X4, M1035 (2310-01-146-7194);
M1035A1 (2310-01-371-9585) (EIC: BBW); M1035A2 (2310-01-380-8290) (EIC: BB9).
REPORTING OF ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this publication. If you find any mistakes or if you know of a way to improve the procedures, please
let us know. (Army) Submit your DA Form 2028-2 (Recommended Changes to Equipment Technical Publications), through
the Internet, on the Army Electronic Product Support (AEPS) website. The Internet address is http://aeps.ria.army.mil.
If you need a password, scroll down and click on “ACCESS REQUEST FORM.” The DA Form 2028 is located in the
ONLINE FORMS PROCESSING section of the AEPS. Fill out the form and click on SUBMIT. Using this form on the
AEPS will enable us to respond quicker to your comments and better manage the DA Form 2028 program. You may also
mail, fax or email your letter, DAForm 2028, or DAForm 2028-2 direct to: Commander, U.S. Army Tank-automotive and
Armaments Command, ATTN: AMSTA - L C - C I P - W T, Rock Island, IL 61299-7630. The email address is
amsta-ac-nml@ria.army.mil. The fax number is DSN 793-0726 or Commercial (309) 782-0726. (Marine Corps) Submit
NAVMC 10722 to Commander Code 835-2, Marine Corps Logistic Base, 814 Radford Boulevard, Albany, GA 31704-1128.
This manual is published in three parts. TM 9-2320-280-20-1 contains chapters 1 and 2, TM 9-2320-280-20-2
contains chapters 3 through 9, and TM 9-2320-280-20-3 contains chapters 10 through 13 and Appendices A
through G.
This manual contains a table of contents and alphabetized index for chapters 10 through 13.
* This publication supersedes TM 9-2320-280-20-3 dated 1 November 1993 and all changes.
Change 1 i
TM 9-2320-280-20-3
VOLUME 3 OF 3 Page
CHAPTER 10 BODY AND ACCESSORIES MAINTENANCE ...................... 10-1

Section I. Body Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
II. Body Accessories Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-115
III. Winch Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-179
CHAPTER 11 SPECIAL PURPOSE BODIES MAINTENANCE ..................... 11-1

Section I. Weapon Carrier Body Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
II. S250 Shelter Carrier Body Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-161
III. Ambulance Body Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-173
CHAPTER 12 SPECIAL PURPOSE KITS MAINTENANCE ....................... 12-1

Section I. Deep Water Fording Kit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
II. Troop Seat Kit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-19
III. 100 Ampere Alternator Kit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-23
IV. Arctic Winterization Kits Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-36
V. Arctic Winterization Crew Top Kits Maintenance . . . . . . . . . . . . . . . . . . . . . . . 12-104
VI. Troop/Cargo Winterization Kit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 12-114
VII. Communications Kits Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-201
VIII. 81 MM Mortar Kit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-235
IX. Traversing Bar Kit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-251
X. M1097, M1097A1, M1097A2, and M1123 Special Purpose Kits Maintenance . . . 12-254
XI. Accessory Kits Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-282
XII. Cargo Barrier and Net Kit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-314
CHAPTER 13 PREPARATION FOR STORAGE OR SHIPMENT .................... 13-1

Section I. General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
II. Preparation for Storage and Shipment .............................. 13-2
APPENDIX A REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

APPENDIX B MAINTENANCE ALLOCATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
APPENDIX C EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST ........... C-1
APPENDIX D ILLUSTRATED LIST OF MANUFACTURED ITEMS ................... D-1
APPENDIX E TORQUE LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
APPENDIX F WIRING DIAGRAMS AND SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1
APPENDIX G MANDATORY REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1
INDEX ........................................................... Index 1
ii Change 1
TM 9-2320-280-20-3
CHAPTER 10
BODY AND ACCESSORIES MAINTENANCE
Section I. BODY MAINTENANCE
1 0 - 1 . BODY MAINTENANCE TASK SUMMARY
TASK PROCEDURES PAGE

PARA. NO.
10-2. Fuel Filler Housing Replacement 10-3
10-3. Hood Latch and Bracket Replacement 10-4
10-4. Hood Prop Rod and Bracket Maintenance 10-6
10-5. Hood and Hinge Replacement 10-8
10-6. Outer Hood Seal Replacement 10-11
10-7. Side Hood Stop Replacement 10-12
10-8. Center Hood Stop Replacement 10-13
10-9. Footman Loop and Strap Replacement 10-14
10-9.1. Jack Retaining Strap Replacement 10-14.1
10-10. Center Hood Stop Guide Replacement 10-15
10-11. Front Hood Screen Replacement 10-16
10-12. Hood Grille and Screen Replacement 10-17
10-13. Door Handle Assembly Maintenance 10-18
10-14. Fixed Rear Door Replacement 10-21
10-15. Engine Access Cover Maintenance 10-22
10-16. Engine Access Cover Flexible Latch and 10-27
Holddown Strike Replacement
10-17. Engine Left Splash Shield Maintenance 10-28
10-18. Engine Left Splash Shield Access Cover Replacement 10-32
10-19. 3.5-Ton Jack Stowage Bracket and Cover Replacement 10-33
10-20. Engine Right Splash Shield Maintenance 10-34
10-21. Windshield Glass and Weatherstrip Replacement 10-38
10-22. Windshield Ballistic Glass Replacement 10-40
10-23. Windshield Assembly Maintenance 10-42
10-24. Windshield Retention Bracket Replacement 10-44
10-25. Left Outer Cowl Insulation Replacement 10-45
10-26. Left Front Cowl Insulation Replacement 10-46
10-27. Right Front Cowl Insulation Replacement 10-47
10-28. Tunnel Interior Side Insulation Replacement 10-48
10-29. Rear Seat Floor Insulation Replacement 10-50
10-30. Right Inner Cowl Insulation Panel Replacement 10-51
10-31. Left Inner Cowl Insulation Panel Replacement 10-52
10-31.1. Cargo Floor Access Cover Maintenance (M1123) 10-56.2
10-32. Driver’s Seat Frame Replacement 10-58
10-33. Driver’s Seat and Seat Back Cushions Replacement 10-60
Change 1 10-1
TM 9-2320-280-20-3
1 0 - 1 . BODY MAINTENANCE TASK SUMMARY (Cont’d)

PARA. NO.
10-34. Companion Seat Back Replacement 10-61
10-35. Companion Seat and Battery Box Cover Replacement 10-62
10-36. Battery Box Cover Latch Replacement 10-63
10-37. Companion Seat and Seat Back Cushions Replacement 10-64
10-38. Driver's Seat Assembly Replacement 10-65
10-39. Driver's Seat Assembly Maintenance 10-66
10-40. Battery Box Cover Catch Replacement 10-68
10-41. Companion Seat Assembly and Battery Box 10-69
Cover Replacement
10-42. Companion Seat Assembly Maintenance 10-70
10-43. Passenger Seat and Storage Compartment 10-71
Cover Replacement
10-44. Passenger Seat and Storage Compartment 10-72
Latch Replacement
10-45. Passenger Seat Back Replacement 10-73
10-46. Passenger Seat and Seat Back Cushions Replacement 10-74
10-47. Seatbelt Assembly Replacement 10-75
10-48. Three Point Seatbelt Maintenance 10-76
10-48.1. Three Point Seatbelt Maintenance 10-80.2
(M996, M996A1, M997, M997A1, and M997A2)
10-49. Three Point Seatbelt Brackets Replacement 10-82
10-49.1. Three Point Seatbelt Brackets Replacement 10-82.2
(M996, M996A1, M997, M997A1, and M997A2)
10-50. Pioneer Tool Stowage Tray Maintenance 10-84
10-51. Pioneer Tool Stowage Tray Mounting Bracket Replacement 10-86
10-52. Pioneer Tool Stowage Tray Latch Striker Replacement 10-87
10-53. Cargo Bulkhead Replacement 10-88
10-54. Cargo Bulkhead Mounting Brackets Replacement 10-89
10-55. Cargo Barrier Extension Maintenance 10-90
10-56. Cargo Tiedown Replacement 10-92
10-57. Fire Extinguisher Bracket Replacement 10-93
10-58. Fire Extinguisher Support Replacement 10-94
10-59. Driver's Seat Retainer Plate Assembly Replacement 10-95
10-60. Tailgate Chain and Brackets Replacement 10-96
10-61. Tailgate Replacement 10-98
10-62. Tailgate Upper Hinge Replacement 10-100
10-63. Mud Flap Installation 10-102
10-64. Body Hinge Mount Replacement 10-103
10-65. Airlift Bracket to Hood Seal Replacement 10-104
10-66. Body Repair 10-105
10-67. “B” Pillar Replacement 10-111
10-68. M11 Decontamination Brackets Installation 10-112
10-2 Change 1
TM 9-2320-280-20-3
10-2. FUEL FILLER HOUSING REPLACEMENT

This task covers:
a. Removal b. Installation
INITIAL SETUP
Manual Reference
General mechanic’s tool kit TM 9-2320-280-24P
automotive (Appendix B, Item 1)
1. Remove filler cap “T” handle (1) and filler cap (2) from filler spout (6).
2. Remove three nuts (7), washers (4), capscrews (3), and washers (4) from filler housing (5) and filler spout (6).
3. Remove six screws (11) and washers (10) from fuel filler housing (5) and right outer wheelhouse panel (8).
4. Push filler cap (2) through filler housing (5) and remove filler housing (5).
5. Inspect speed nuts (9) for presence or damage. Replace if defective or missing.
1. Pull filler cap (2) through filler housing (5) and install housing (5) on right outer wheelhouse panel (8).
2. Secure filler housing (5) to right outer wheelhouse panel (8) with six washers (10) and screw (11).
Tighten screws (11) to 20 lb-in. (2 N.m).
3. Secure filler housing (5) to filler spout (6) with three washers (4), capscrews (3), washers (4), and nuts (7).
4. Install filler cap (2) on filler spout (6) with “T” bade (1).
10-3
TM 9-2320-280-20-3
10-3. HOOD LATCH AND BRACKET REPLACEMENT

This task covers:
a. Removal c. Assembly
b. Disassembly d. Installation
INITIAL SETUP:
Tools Manual References
General mechanic’s tool kit: TM 9-2320-280-10
automotive (Appendix B, Item 1) TM 9-2320-280-24P
Materials/Parts Equipment Condition
Seven locknuts (Appendix G, Item 58) Hood raised and secured (TM 9-2320-280-10).
Cotter pin (Appendix G, Item 21)
Spring pin (Appendix G, Item 233)
a. Removal
NOTE
If only the rubber latch is to be replaced, the spring pin does not
have to be completely out of base.
1. Remove two locknuts (6), washers (4), capscrews (3), and washers (4) from base (7) and body (5).
Discard locknuts (6).
2. Remove spring pin (2) from latch (10) and base (7).
3. Remove two locknuts (16), washers (17), capscrews (12), and latch bracket (13) from hood (15). Discard
locknuts (16).
4. Remove three locknuts (18), washers (19), capscrews (21), latch stop bracket (20), and latch plate (14)
from hood (15). Discard locknuts (18).
b. Disassembly
Remove cotter pin (1), pin (8), two rollers (9), and hood latch (11) from latch (10). Discard cotter pin (1).
Install hood latch (11) on latch (10) with two rollers (9), pin (8), and cotter pin (1).
d. Installation
1. Install latch plate (14) and latch stop bracket (20) on hood (15) with three capscrews (21), washers (19),
and locknuts (18).
2. Install latch bracket (13) on latch plate (14) with two capscrews (12), washers (17), and locknuts (16).
Tighten locknuts (16) and (18) to 10 lb-ft (14 N~m).
3. Install latch (10) on base (7) with spring pin (2).
4. Install base (7) on body (5) with two washers (4), capscrews (3), washers (4), and locknuts (6). Tighten
capscrews (3) to 6 lb-ft (8 Nom).
10-4
TM 9-2320-280-20-3
10-3. HOOD LATCH AND BRACKET REPLACEMENT (Cont’d)
FOLLOW-ON TASK: secure hood (TM 9-2320-280-10).
10-5
TM 9-2320-280-20-3
10-4. HOOD PROP ROD AND BRACKET MAINTENANCE

This task covers:
a. Removal d Assembly
b. Disassembly e. Installation
c. Inspection
lNITIAL SETUP:
Tools Equipment Condition
General mechanic’s tool kit: Hood raised and secured (TM 9-2320-280-10).
General Safety Instructions
Materials/Parts Hood must be supported during hood prop rod and
Four lockwashers (Appendix G, Item 110) bracket replacement.
Locknut (Appendix G, Item 65)
Manual References
TM 9-2320-280-10
TM 9-2320-280-24P
WARNING
Hood must be supported during hood prop rod and bracket replace
ment. Failure to support hood may cause injury to personnel or
damage to equipment.
1. Remove cotter pin (4), washer (3), hood prop rod (2), and washer (3) from hood (1). Discard cotter
pin (4).
2. Remove four screws (8), lockwashers (7), bracket (6), and hood prop rod (2) from airlift bracket (5).
Discard lockwashers (7).
b. Disassembly
1. Remove hood prop rod (2) from eyebolt (15).
2. Remove locknut (9), washer (10), bushing (16), spring (11), eyebolt (15), and washer (14) from bracket (6).
Discard locknut (9).
3. Remove snapring (12) and bushing (13) from bracket (6).
Inspect bushing (13), bushing (16), and spring (11) for cracks, wear, or distortion. Replace bushing (13), (16),
or spring (11) if cracked, worn, or distorted.
I d. Assembly
1. Install bushing (13) on bracket (6) with snapring (12).
NOTE
Length of spring with bracket assembled is 2-1/4 in. (5.7 cm).
2. Install washer (14), eyebolt (15), and spring (11) on bracket (6) with bushing (16), washer (10), and locktnut (9).
3. Install hood prop rod (2) into eyebdt (15).
10-6
TM 9-2320-280-20-3
10-4. HOOD PROP ROD AND BRACKET MAINTENANCE (Cont'd)
1. Install hood prop rod (2) and bracket (6) on airlift bracket (5) with four lockwashers (7) and screws (8).
Tighten screws (8) to 6 lb-ft (8 N.m).
2. Install washer (3) and hood prop rod (2) on hood (1) with washer (3) and rotter pin (4).
FOLLOW-ON TASK: Lower and secure hood (TM 9-2320-280-10).
10-7
TM 9-2320-280-20-3
1 0 - 5 . HOOD AND HINGE REPLACEMENT
This task covers:

a. Removal c. Alignment
b. Installation
INITIAL SETUP:
TM 43-0139
Materials/Parts
Sealing compound (Appendix C, Item 45) Equipment Condition
Three cotter pins (Appendix G, Item 17) • Battery ground cable disconnected (para. 4-73).
Four locknuts (Appendix G, Item 58) • Hood raised and secured (TM 9-2320-280-10).
Personnel Required General Safety Instructions
One mechanic Hood must be supported during removal and
One assistant installation.
WARNING
Hood must be supported during removal and installation. Failure to
support hood may cause injury to personnel and damage to equipment.
NOTE
Hood surface has a thin layer of gel coat that can seem cracked, in
a spiderweb pattern, due to hood flexing. No repair is necessary.
Any other cracks should be repaired to prevent further damage.
a. Removal
1. Disconnect connector plug (11) from connector receptacle (7).
2. Remove two cotter pins (1), washers (2), hinge pins (13), and washers (2) from two upper hinge
halves (14) and lower hinge halves (12). Discard cotter pins (1).
3. Remove cotter pin (17), washer (18), hood prop rod (19), and washer (18) from hood (15). Discard
cotter pin (17).
4. Remove hood (15).
NOTE
• Perform steps 5 and 6 if replacing hinges.
• Note position of hinge halves prior to removal, for installation.
5. Remove four capscrews (4), washers (3), two upper hinge halves (14), and hinge plates (16) from
hood (15).
6. Remove four locknuts (9), two hinge plates (8), four capscrews (5), washers (6), and two lower hinge
halves (12) from brackets (10). Discard locknuts (9).
b. Installation
NOTE
Perform steps 1 through 3 if hinges were removed.
1. Install two lower hinge halves (12) on brackets (10) with four washers (6), capscrews (5), two
plates (8), and four locknuts (9). Do not tighten locknuts (9).
2. Apply sealing compound to hinge plates (16) and install hinge plates (16) to hood (15).
10-8 Change 1
TM 9-2320-280-20-3
1 0 - 5 . HOOD AND HINGE REPLACEMENT (Contd)
3. Install two upper hinge halves (14) on hood (15) with four washers (3) and capscrews (4). Tighten
capscrews to 28 lb-ft (38 N•m).
4. Install hood (15) and align two upper hinge halves (14) with lower hinge halves (12).
5. Secure two upper hinge halves (14) to lower hinge halves (12) with washers (2), hinge pins (13),
washers (2), and cotter pins (1).
6. Connect connector plug (11) to connector receptacle (7).
7. Install washer (18) and hood prop rod (19) on hood (15) with washer (18) and cotter pin (17).
Change 1 10-9
TM 9-2320-280-20-3
10-5. HOOD AND HINGE REPLACEMENT (Cont’d)
c. Alignment
1. Lower hood (4) and check alignment of hood stop guide (3) with center hood stop (2) on “A”
pillar (1), and hood catch (5) with body latch (6).
NOTE
Upper and lower hinge halves contain slotted mounting holes to
allow for adjustment.
2. With hood (4) lowered and secured and alignment correct, tighten four lower hinge half attaching
locknuts (7) to 60 lb-ft (81 Nom).
NOTE
After hood alignment is completed, some contact may occur
between hood and left mirror bracket. If contact exists, use file and
trim about 1/4 in. (6.4 mm) off left comer and edge of hood. Trim
until hood closes without hitting left mirror bracket. Touch up trim
with paint (refer to TM 43-0139).
FOLLOW-ON TASKS: . Lower and secure hood (TM 9-2320-280-10).

● Connect battery ground cable (para. 4-73).
10-10
TM 9-2320-280-20-3
10-6. OUTER HOOD SEAL REPLACEMENT

This task covers:
INITIAL SETUP:
TM 9-2320-280-10
TM 9-2320-280-24P
a. Removal
Remove two capscrews (4), seal retainer (3), and hood seal (2) from body (1).
b. Installation
Install hood seal (2) on body (1) with seal retainer (3) and two capscrews (4).
FOLLOW-ON TASK Lower and secure hood (TM 9-2320-280-10).
10-11
TM 9-2320-280-20-3
10-7. SIDE HOOD STOP REPLACEMENT

This task covers:
INITIAL SETUP:
Two locknuts (Appendix G, Item 58) Hood raised and secured (TM 9-2320-280-10).
a. Removal
Remove two locknuts (6), washers (5), capscrews (3), washers (2), and side hood stop (1) from body (4).
b. Installation
Install side hood stop (1) on body (4) with two washers (2), capscrews (3), washers (5), and locknuts (6).
Tighten capscrews (3) to 6 lb-ft (8 Nom)
10-12
TM 9-2320-280-20-3
10-8. CENTER HOOD STOP REPLACEMENT

This task covers:
INITIAL SETUP:
Manual References
TM 9-2320-280-10
TM 9-2320-280-24P
a. Removal
Remove two capscrews (1), washers (2), center hood stop (3), and plate (4) from “A” beam (5).
I b. Installation
Install center hood stop (3) and plate (4) on “A” beam (5) with two washers (2) and capscrews (1). Tighten
capscrews (1) to 12 lb-ft (16 N.m).
10-13
TM 9-2320-280-20-3
10-9. FOOTMAN LOOP AND STRAP REPLACEMENT

This task covers:
INITIAL SETUP:

Two locknuts (Appendix G, Item 60) Rear end of cargo shell door raised
(TM 9-2320-280-10).
NOTE
All footman loops and straps for stowage and tiedowns are replaced
basically the same. This procedure covers the night sight battery
case footman loop and strap.
a. Removal
1. Remove two locknuts (4), screws (1), and footman loop (2) from wheelhouse (3). Discard locknuts (4).
2. Remove strap (5) from footman loop (2).
b. Installation
Install strap (5) on footman loop (2) and wheelhouse (3) with two screws (1) and locknuts (4). Tighten
locknuts (4) to 16-30 lb-in. (2-3‘N.m).
FOLLOW-ON TASK Close cargo shell door (TM 9-2320-280-10).
10-14
TM 9-2320-280-20-3
1 0 - 9 . 1 . JACK RETAINING STRAP REPLACEMENT

This task covers:
INITIAL SETUP:
Applicable Models Materials/Parts
M1097A1, M1097A2, M1123 Four locknuts (Appendix G, Item 91)
Tools
Manual References
General mechanic’s tool kit:
a. Removal
1. Slide driver’s seat (1) forward.

2. Remove four locknuts (7), washers (6), screws (4), two footman loops (2), and jack retaining strap (3)
from vehicle floor (5). Discard locknuts (7).
b. Installation
1. Install jack retaining strap (3) and two footman loops (2) on vehicle floor (5) with four screws (4),
washers (6), and locknuts (7).
2. Slide driver’s seat (1) backward.
Change 1 10-14.1/(10-14.2 blank)

TM 9-2320-280-20-3
10-10. CENTER HOOD STOP GUIDE REPLACEMENT

This task covers:
INITIAL SETUP:
Six locknuts (Appendix G, Item 58) Rear end of cargo shell door raised
(TM 9-2320-280-10).
Remove six locknuts (5), washers (2), capscrews (1), washers (2), two guide plates (3), and guide brackets (4)
from hood (6). Discard locknuts (5).
Install two guide plates (3) and guide brackets (4) on hood (6) with six washers (2), capscrews (1),
washers (2), and locknuts (5). Tighten locknuts (5) to 10 lb-ft (14 N.m).
10-15
TM 9-2320-280-20-3
1 0 - 1 1 . FRONT HOOD SCREEN REPLACEMENT
This task covers:

INITIAL SETUP:
Applicable Models Manual References
M998, M998A1, M1035, M1035A1, M1035A2, TM 9-2320-280-10
M1037, M1038, M1038A1, M1042 TM 9-2320-280-24P
Materials/Parts
Sealant (Appendix C, Item 38)
a. Removal
1. Remove three nuts (7), washers (6), and carriage bolts (8) from front hood screen (5) and hood (1).
2. Remove three capscrews (2), harness clamps (3), washers (4), and front hood screen (5) from hood (1).
b. Installation
1. Apply sealant to threads of capscrews (2).

2. Install front hood screen (5) on hood (1) with three washers (4), harness clamps (3), and capscrews (2).
Tighten capscrews (2) to 20-30 lb-in. (2-3 N•m).
3. Secure front hood screen (5) to hood (1) with three carriage bolts (8), washers (6), and nuts (7).
Tighten nuts (7) to 21 lb-ft (29 N•m).
10-16 Change 1
TM 9-2320-280-20-3
10-12. HOOD GRILLE AND SCREEN REPLACEMENT

This task covers:
lNITIAL SETUP:
M998, M998A1, M1035, M1035A1, M1035A2, Six locknuts (Appendix G, Item 58)
M1037, M1038, M1038A1, M1042 Six locknuts (Appendix G, Item 60)
Equipment Condition
Hood raised and secured (TM 9-2320-280-10).
1. Remove six locknuts (5), washers (2), capscrews (1), washers (2), and grille (3) from hood (4). Discard
locknuts (5).
2. Remove six locknuts (7), washers (8), screws (10), washers (9), and screen (6) from grille (3). Discard
locknuts (7).
b. Installation
1. Install screen (6) on grille (3) with six washers (9), screws (10), washers (8), and locknuts (7).
Tighten locknuts (7) to 6 lb-ft (8 N=m).
2. Install grille (3) on hood (4) with six washers (2), capscrews (1), washers (2), and locknuts (5).
Tighten locknuts (5) to 7 lb-ft (10 Nom).
10-17
TM 9-2320-280-20-3
10-13. DOOR HANDLE ASSEMBLY MAINTENANCE I
This task covers:

a. Removal c. Installation
b. Repair
INITIAL SETUP:
M998, M998A1, M1035, M1035A1, M1035A2, Adhesive (Appendix C, Item 7)
M1037, M1038, M1038A1, M1042 Spring pin (Appendix G, Item 234)
General mechanic’s tool kit: TM 9-2320-280-24P
NOTE
Some door handle assemblies may separate. To prevent or fix door
handle assembly separation, perform step b.
1. Remove screw (5), inside door handle (4), and door handle spring (6) from door frame (7) and outside
door handle (1).
2. Remove outside door handle (1) and washer (3) from door frame (7).
b. Repair
Repair procedures for all door handle assemblies are basically the
same. This procedure covers the left front door handle assembly.
1. Tighten screw (5) on inside door handle (4) to 15 lb-in. (1.7 Nom).
NOTE
Q If screw will secure inside door handle, perform steps 2 and 3.
s If screw will not secure inside door handle, perform steps 4
through 10.
2. Locate, mark, and drill 0.125-in. (3.2 mm) diameter hole (9) through inside door handle (4) and
outside door handle (1).
3. Install spring pin (8) through inside door handle (4) and outside door handle (1).
NOTE
Inside door handle can separate from outside door handle without
removing screw.
4. Remove inside door handle (4) and door handle spring (6) from outside door handle (1) and door
frame (7).
5. Remove outside door handle (1) and washer (3) from door frame (7).
6. Remove screw (5) and insert (2) from inside door handle (4).
7. Apply adhesive to outside of insert (2) and install insert (2) in outside door handle (1). Allow adhesive
to cure for five minutes.
8. Install outside door handle (1) and washer (3) on door be (7).
9. Install inside door handle spring (6) and inside door handle (4) on outside door handle (1) and door
frame (7) with screw (5). Tighten screw (5) to 15 lb-in. (1.7 N*m).
10. Perform steps 2 and 3.
10-18
TM 9-2320-280-20-3
10-13. DOOR HANDLE ASSEMBLY MAINTENANCE (Cont’d)
10-19
TM 9-2320-280-20-3
10-13. DOOR HANDLE ASSEMBLY MAINTENANCE (Cont’d)
c. Installation
1. Install washer (2) and outside door handle (1) on door frame (6).
2. Install door handle spring (5) and inside door handle (3) on outside door handle (1) in door frame (6).
3. Place outside door handle (1) in horizontal position, and place inside door handle (3) in vertical
position with grip end of handle pointing to top of door.
4. Install inside door handle (3) on outside door handle (1) and door frame (6) with screw (4). Tighten
screw (4) to 15 lb-in. (1.7 Nom).
10-20
TM 9-2320-280-20-3
10-14. FIXED REAR DOOR REPLACEMENT

This task covers:
INITIAL SETUP:
M998, M998A1, M1037, M1038, M1038A1, TM 9-2320-280-24P
M1042, M1097, M1097A1, M1097A2
Equipment Condition
Tools Troop seat removed, if installed (para. 12-18).
General mechanic’s tool kit
Materials/Parts
Door seals (Appendix G, Item 29)
a. Removal
1. Remove four capscrews (6) and washers (7) from fixed rear door (4) and “B” pillar (1).
2. Remove locking pin (3) and fixed rear door (4) from body (2).
3. Remove seals (5) from fixed rear door (4). Discard seals (5).
b. Installation
1. Install seals (5) on fixed rear door (4).
2. Install fixed rear door (4) on body (2) with locking pin (3).
3. Install fixed rear door (4) on “B” pillar (1) with four washers (7) and capscrews (6). Tighten
FOLLOW-ON TASK Install troop seat, if removed (para. 12-18).
10-21
TM 9-2320-280-20-3
10-15. ENGINE ACCESS COVER MAINTENANCE

This task covers:
INITIAL SETUP
Equipment Condition
Materials/Parts Front radio rack removed (para. 12-132).
Two locknuts (Appendix G, Item 65)
Eighteen rivets (Appendix G, Item 178)
1. Unlatch two flexible latches (1) from keepers (2) on engine access cover holddown brackets (3).
2. Unlatch two engine access cover holddown latches (6) from two engine access cover holddown
strikes (7).
3. Turn two ring studs (5) and remove engine access cover (4).
I b. Disassembly
NOTE
For rivet replacement instructions, refer to para. 10-66.
1. Remove seven rivets (10) and retainers (9) and remove insulation (11).
2. Remove seal (8) from access cover (4).
10-22
TM 9-2320-280-20-3
10-15. ENGINE ACCESS COVER MAINTENANCE (cont’d)
10-23
TM 9-2320-280-20-3
I 10-15. ENGINE ACCESS COVER MAINTENANCE (Cont’d)

3. Remove four retaining rings (8), two washers (7), ring studs (6), and washers (7) from access cover (5).
4. Remove two locknuts (9), shoulder bolts (13), and latches (14) from access cover (5). Discard lock-
nuts (9).
5. Remove two rivets (12), backing plates (10), and guide plates (11) from access rover (5).
6. Remove two rivets (1) and keepers (2) from holddown brackets (3).
7. Remove four rivets (4), nuts (15), washers (16), capscrews (18), two holddown brackets (3), and
backing plates (17) from access cover (5).
I c. Assembly I
1. Install two holddown brackets (3) and backing plates (17) on access cover (5) with four rivets (4),
capscrews (18), washers (16), and nuts (15).
2. Install two keepers (2) on holddown brackets (3) with rivets (1).
3. Install two backing plates (10) and guide plates (11) on access cover (5) with rivets (12).
4. Install two latches (14) on plates (11) and access cover (5) with shoulder bolts (13) and locknuts (9).
5. Install two washers (7) and ring studs (6) on access cover (5) with washers (7) and four retaining
rings (8).
6. Install seal (19) on access cover (5).
7. Install insulation (22) on access cover (5) with seven retainers (20) and rivets (21).
10-24
TM 9-2320-280-20-3
10-15. ENGINE ACCESS COVER MAINTENANCE (Cont’d)
10-25
TM 9-2320-280-20-3
10-15. ENGINE ACCESS COVER MAINTENANCE (Cont’d)
1. Install access cover (4) with two ring studs (5).

2. Install two holddown latches (6) on holddown strikes (7).
3. Latch two flexible latches (1) to keepers (2) on access cover holddown brackets (3).
FOLLOW-ON TASK: Install front radio rack (para. 12-132).
10-26
TM 9-2320-280-20-3
10-16. ENGINE ACCESS COVER FLEXIBLE LATCH AND HOLDDOWN STRIKE

REPLACEMENT
This task covers:
lNITIAL SETUP:
Equipment Condition
Materials/Parts Engine access cover removed (para. 10-15).
Four rivets (Appendix G, Item 179)
a. Removal
NOTE
1. Remove two rivets (5) and holddown strike (4) from body (3).
2. Remove two rivets (1) and flexible latch (2) from cargo floor (6).
b. Installation
1. Install flexible latch (2) on cargo floor (6) with two rivets (1).
2. Install holddown strike (4) on body (3) with two rivets (5).
FOLLOW-ON TASK Install engine access cover (para. 10-15).
10-27
TM 9-2320-280-20-3
10-17. ENGINE LEFT SPLASH SHIELD MAINTENANCE

This task covers:
INITIAL SETUP:
Equipment Condition
Materials/Parts l Battery ground cable disconnected (para. 4-73).
Thirteen locknuts (Appendix G, Item 65) l Hood prop rod and bracket removed (para. 10-4).
Five lockwashers (Appendix G, Item 109)
Nut and lockwasher assembly General Safety Instructions
(Appendix G, Item 149) Hood must be supported during removal and
Four rivets (Appendix G, Item 180) installation.
WARNING
Hood must be supported during removal and installation. Failure to

support hood may cause injury to personnel and damage to equipment.
NOTE
l Left splash shield maintenance is the same for all vehicles, except
M998, M998A1, M1035, M1035A1, M1035A2, M1037, M1038,
M1038A1, and M1042 vehicles do not have an armor plate
attached to side of shield.
Q The left splash shield can be modified with an access cover
which will provide easier access to transmission oil cooler lines, at
commander’s discretion. Refer to appendix D, Figs. D-86 and D-87.
a. Removal
1. Disconnect hood harness (27) from connector receptacle (30).

2. Remove locknut (3), washer (2), capscrew (24), and washer (2) from splash shield (15) and support
bracket (1). Discard locknut (3).
3. Remove locknut (10), washer (11), washer (12), capscrew (20), and washer (11) from splash
shield (15) and airlift bracket (9). Discard locknut (10).
4. Remove capscrew (21), lockwasher (22), and washer (23) from splash shield (15) and airlift
bracket (9). Discard lockwasher (22).
5. Remove four screws (28), lockwashers (29), and connector receptacle (30) from bracket (32).
6. Remove nut and lockwasher assembly (39) and screw (37) from harness and clamp (38) and
splash shield (15). Discard nut and lockwasher assembly (39).
7. Remove locknut (13), washer (14), capscrew (19), washer (14), and splash shield (15) from
b.Disassembly
NOTE
Perform step 1 only if vehicle has an armor plate.
1. Remove locknut (33), washer (34), capscrew (36), washer (34), and armor plate (35) from splash
shield (15). Discard locknut (31).
10-28
TM 9-2320-280-20-3
10-17. ENGINE LEFT SPLASH SHIELD MAINTENANCE (Cont'd)
2. Remove seven locknuts (8), washers (7), capscrews (6), seal retainers (4), and seal (5) from splash
shield (15). Discard locknuts (8).
3. Remove two locknuts (25), washers (26), capscrews (31), washers (26), and bracket (32) from splash
NOTE
For rivet replacement instructions refer to para. 10-66.
4. Remove four rivets (18) and bushing (17) from splash shield (15).
10-29
TM 9-2320-280-20-3
10-17. ENGINE LEFT SPLASH SHIELD MAINTENANCE (Cont’d)
1. Install bushing (17) on splash shield (15) with four rivets (18).
2. Install bracket (32) on splash shield (15) with two washers (26), capscrews (31),
washers (26), and locknuts (25). Tighten locknuts (25) to 6 lb-ft (8 Nom).
3. Install seal (5) and seal retainers (4) on splash shield (15) with seven capscrews (6), washers (7), and
locknuts (8).
NOTE
4. Install armor plate (35) on splash shield (15) with washer (34), capscrew (36),
washer (34), and locknut (33). Tighten locknut (33) to 15 lb-ft (20 N-m).
d. Installation
1. Install splash shield (15) on bracket (16) with washer (14), capscrew (19), washer (14), and
locknut (13).
2. Install harness and clamp (38) on splash shield (15) with screw (37) and nut and lockwasher
assembly (39).
3. Install connector receptacle (30) on bracket (32) with four lockwashers (29) and
screws (28).
4. Install splash shield (15) to airlift bracket (9) with washer (23), lockwasher (22), and capscrew (21).
Tighten capscrew (21) to 10 lb-ft (14 Nom).
5. Install splash shield (15) on airlift bracket (9) with washer (11), capscrew (20), washer (12),
washer (11), and locknut (10). Tighten capscrew (20) to 10 lb-ft (14 Nom).
6. Install splash shield (15) on support bracket (1) with washer (2), capscrew (24), washer (2), and
locknut (3). Tighten capscrew (24) to 6 lb-ft (8 Nom).
7. Connect hood harness (27) to connector receptacle (30).
10-30
TM 9-2320-280-20-3
10-17. ENGINE LEFT SPLASH SHIELD MAINTENANCE (Cont’d)
FOLLOW-ON TASKS: ● Install hood prop rod and bracket (para. 10-4)
10-31
TM 9-2320-280-20-3
10-18. ENGINE LEFT SPLASH SHIELD ACCESS COVER REPLACEMENT

This task covers:
INITIAL SETUP:
M997A2, M1025A2, M1035A2, M1043A2, TM 9-2320-280-10
M1045A2, M1097A2 (or modified vehicles) TM 9-2320-280-24P
1. Remove three capscrews (4), washers (3), and splash shield access cover (5) from engine left splash
shield (1).
2. Inspect spring nuts (2) for damage. Replace, if damaged.
b. Installation
Install splash shield access cover (5) to engine left splash shield (1) with three capscrews (4) and
washers (3).
10-32
TM-9-2320-280-20-3
10-19. 3.5-TON JACK STOWAGE BRACKET AND COVER REPLACEMENT

This task covers:
INITIAL SETUP:
Applicable Models Material/Parts
M997A2, M1025A2, M1035A2, M1043A2, Two lockwashers (Appendix G, Item 109)
M1045A2, M1097A2
Manual References
Tools
TM 9-2320-280-10
Equipment Condition
NOTE
The tools for the jack are stored behind the driver’s seat.
a. Removal
1. Lift two latches (9) on cover (10) and remove cover (10) from bracket (5).
2. Remove two wing nuts (14), spacers (13), washers (12), and jack (11) from bracket (5).
3. Remove nut (6), washer (7), capscrew (8), and washer (7) from bracket (5).
4. Remove two capscrews (4), lock-washers (3), washers (2), and bracket (5) from splash shield (1).
b. Installation
1. Install bracket (5) on splash shield (1) with two washers (2), lockwashers (3), and capscrews (4).
2. Install washer (7), capscrew (8), washer (7), and nut (6) on bracket (5).
3. Install jack (11) on bracket (5) with two washers (12), spacers (13), and wing nuts (14).
4. Install cover (10) on bracket (5).
5. Secure cover (10) on bracket (5) with two latches (9).
(TM 9-2320-280-10).
10-33
TM 9-2320-280-20-3
1 0 - 2 0 . ENGINE RIGHT SPLASH SHIELD MAINTENANCE
This task covers:

INITIAL SETUP:
Twelve locknuts (Appendix G, Item 65) • Hood raised and secured (TM 9-2320-280-10).
Three lockwashers (Appendix G, Item 109) • 3.5-ton jack stowage bracket and cover removed
(M1123 and “A2” series only) (para. 10-19).
NOT E
Right splash shield maintenance is the same for all vehicles, except
M998, M998A1, M1035, M1035A1, M1035A2, M1037, M1038,
M1038A1, and M1042 vehicles do not have an armor plate attached
to side of shield.
a. Removal
1. Remove locknut (7), washer (6), capscrew (8), and washer (6) from splash shield (1) and support
2. Remove locknut (15), washer (16), washer (17), capscrew (19), lockwasher (18), and washer (16)
from splash shield (1) and airlift bracket (4). Discard locknut (15) and lockwasher (18).
3. Remove locknut (21), washer (20), capscrew (10), and fuel line clamp (22) from splash shield (1).
4. Remove two screws (2), lockwashers (3), washers (9) (vehicles without armor plate), and
splash shield (1) from airlift bracket (4). Discard lockwashers (3).
b. Disassembly
1. Remove locknut (14), washer (12), capscrew (11), washer (12), and support plate (13) from splash
shield (1). Discard locknut (14).
10-34 Change 1
TM 9-2320-280-20-3
10-20. ENGINE RIGHT SPLASH SHIELD MAINTENANCE (Cont’d)
10-35
TM 9-2320-280-20-3
10-20. ENGINE RIGHT SPLASH SHIELD MAINTENANCE (Cont'd)

NOTE
2. Remove locknut (2), washer (3), capscrew (4), washer (3), and armor plate (1) from splash shield (5).
3. Remove seven locknuts (10), washers (9), capscrews (7), seal retainers (6), and seal (8) from splash
1. Install seal (8) and seal retainers (6) on splash shield (5) with seven capscrews (7), washers (9), and
locknuts (10).
NOTE
2. Install armor plate (1) on splash shield (5), ensuring capscrew holes align, and secure with washer (3),
capscrew (4), washer (3), and locknut (2). Tighten locknut (2) to 15 lb-ft (20 Nom).
3. Install support plate (15) on splash shield (5), ensuring capscrew holes align, and secure with
washer (14), capscrew (13), washer (14), and locknut (16).
d. Installation
1. Install splash shield (5) on airlift bracket (12) with two washers (31) (vehicles without armor plate),
lockwashers (26), and screws (25).
2. Install fuel line clamp (24) on splash shield (5) with capscrew (11), washer (22), and lochnut (23).
3. Secure splash shield (5) to airlift bracket (12) with lockwasher (20), washer (18), capscrew (21),
washer (19), washer (18), and locknut (17). Tighten capscrew (21) to 10 lb-ft (14 Nom).
4. Secure splash shield (5) to support bracket (27) with washer (28), capscrew (30), washer (28), and
locknut (29). Tighten capscrew (30) to 15 lb-ft (20 N.m).
10-36
TM 9-2320-280-20-3
1 0 - 2 0 . ENGINE RIGHT SPLASH SHIELD MAINTENANCE (Cont'd)
FOLLOW-ON TASKS: • Install 3.5-ton jack stowage bracket and cover (M1123 and “A2” series only)
(para. 10-19).
• Lower and secure hood (TM 9-2320-280-10).
Change 1 10-37
TM 9-2320-280-20-3
1 0 - 2 1 . WINDSHIELD GLASS AND WEATHERSTRIP REPLACEMENT
This task covers:

INITIAL SETUP:
M998, M998A1, M1035, M1035A1, M1035A2, TM 9-2320-280-24P
M1037, M1038, M1038A1, M1042
Equipment Condition
Tools Windshield wiper blade and arm removed
General mechanic’s tool kit: (para. 10-70).
Materials/Parts Eyeshields and gloves are required when installing
Sealant (Appendix C, Item 38) and removing windshield glass.
WARNING
Use eyeshields and gloves when removing and installing
windshield. Glass could shatter causing injury.
a. Removal
1. Remove six capscrews (7) and upper retainer (3) from windshield frame (5).
2. Remove four capscrews (1) and center retainer (2) from windshield frame (5).
3. Remove weatherstrip (4) and glass (6) from windshield frame (5).
4. Clean sealant from windshield frame (5).
b. Installation
1. Apply a 1/8 inch (3 mm) bead of sealing compound to edge of glass (6) and to windshield frame (5).
2. Install weatherstrip (4) on glass (6).
3. Install glass (6) and weatherstrip (4) on windshield frame (5) with center retainer (2) and four
capscrews (1).
4. Apply a thin bead of sealant to top edge of outside weatherstrip (4).
5. Install upper retainer (3) on windshield frame (5) with six capscrews (7).
10-38 Change 1
TM 9-2320-280-20-3
10-21. WINDSHIELD GLASS AND WEATHERSTRIP REPLACEMENT (Cont’d)
FOLLOW-ON TASK: Install windshield wiper blade and arm (para. 10-70).
10-39
TM 9-2320-280-20-3
10-22. WINDSHIELD BALLISTIC GLASS REPLACEMENT I
This task covers:

INITIAL SETUP:
Applicable Models Personnel Required
All except M998, M998A1, M1035, M1035A1, One mechanic
M1035A2, M1037, M1038, M1038A1, M1042 One assistant
General mechanic’s tool kit: Windshield wiper blade and arm removed
automotive (Appendix B, Item 1) (para. 10-70).
Materials/Parts General Safety Instructions
Sealing compound (Appendix C, Item 47) Eyeshields and gloves are required when installing
and removing windshield glass.
Manual References
TM 9-2320-280-24P
Use eyeshields and gloves when removing and installing windshield

glass. Glass could shatter causing injury.
1. Remove six screws (6) and upper retainer (5) from windshield frame (4).
2. Remove four screws (1) and center retainer (2) from windshield frame (4).
3. Remove ballistic glass (3) from windshield frame (4).
4. Clean sealing compound from windshield frame (4).
1. Apply a 1/8 in. (3 mm) bead of sealing compound around windshield frame (4).
2. Position ballistic glass (3) to windshield frame (4) with marking on weatherstrip facing inward.
3. Install center retainer (2) on windshield frame (4) with four screws (1).
4. Install upper retainer (5) on windshield frame (4) with six screws (6).
10-40
TM 9-2320-280-20-3
10-22. WINDSHIELD BALLISTIC GLASS REPLACEMENT (Cont’d)
FOLLOW-ON TASK: Install windshield wiper blade and arm (para. 10-70).
10-41
TM 9-2320-280-20-3
10-23. WINDSHIELD ASSEMBLY MAINTENANCE I
This task covers:

INITIAL SETUP:
Applicable Models
M998, M998A1, M1035, M1035A1, M1035A2, ● Soft top enclosure removed, if install.
M1037, M1038, M1038A1, M1042 (TM 9-2320-280-10).
s Windshield wiper blade and arm removed
ToolS (para. 10-70).
General mechanic’s tool kit: . Windshield wiper linkage removed (para. 10-73).
automotive (Appendix B, Item 1) l Windshield wiper arm pivots removed
(para. 10-74).
Personnel Required
One mechanic General Safety Instructions
One assistant Windshield must be supported during removal and
installation.
Manual References
TM 9-2320-280-10
TM 9-2320-280-24P
Windshield must be supported during removal and installation.

Failure to support windshield may cause injury to personnel or
a. Removal
1. Remove five hitch pins (5) from five hinge pins (6).
2. Remove five hinge pins (6) from upper hinge halves (2) and lower hinge halves (4).
3. Remove grommet (11) from “A” pillar (12) and remove jumper harness (10).
4. Remove windshield assembly (1) from “A” pillar (12).
5. Remove two seals (3) from windshield assembly (1).
6. Clean remains of seal (3) from windshield assembly (1).
b. Disassembly
1. Remove thirteen screws (9), former (8), and seal (7) from windshield assembly (1).
2. Clean remains of seal (7) from windshield assembly (1).
1. Peel paper backing from seal (7) and install seal (7) on windshield assembly (1).
2. Install former (8) on seal (7) and windshield assembly (1) with thirteen screws (9).
d. Installation
1. Peel paper backing from two seals (3) and install seals (3) on windshield assembly (1).
2. Install windshield assembly (1) on “A” pillar (12).
3. Install jumper harness (10) on windshield center piller (13) and install grommet (11) on “A” pillar (12).
4. Install upper hinge halves (2) on lower hinge halves (4) with five hinge pins (6).
5. Install five hitch pins (5) in hinge pins (6).
10-42
TM 9-2320-280-20-3
10-23. WINDSHIELD ASSEMBLY MAINTENANCE (Cont’d)
FOLLOW-ON TASKS: Q Install windshield wiper arm pivots (para. 10-74).

● Install windshield wiper linkage (para. 10-73).
Q Install windshield wiper blade and arm (para. 10-70).
c Install soft top enclosure, if removed (TM 9-2320-280-10).
10-43
TM 9-2320-280-20-3
10-24. WINDSHIELD RETENTION BRACKET REPLACEMENT

This task covers:
a Removal b. Installation
INITIAL SETUP
M997A2, M1025A2, M1035A2, Four lockwashers (Appendix G, Item 109)
M1043A2, M1045A2, M1097A2 Manual References
Tools TM 9-2320-280-24P
a. Removal
1. Remove four capscrews (2), lockwashers (3), and retention bracket (1) from windshield frame (5).
2. Inspect four nut inserts (4) for damage. Replace if damaged.
Install retention bracket (1) on windshield (5) with four lockwashers (3) and capscrews (2).
10-44
TM 9-2320-280-20-3
I 10-25. LEFT OUTER COWL INSULATION REPLACEMENT

This task covers:
INITIAL SETUP:
Materials/Parts
Lockwasher (Appendix G, Item 108)
Remove locknut (4), capscrew (1), lockwasher (2), clamp (6), wiring harness (7), and insulation (3) from
cowl (5). Discard lockwasher (2) and locknut (4).
Install insulation (3) and wiring harness (7) on cowl (5) with clamp (6), lockwasher (2), capscrew (1), and
locknut (4).
10-45
TM 9-2320-280-20-3
1 0 - 2 6 . LEFT FRONT COWL INSULATION REPLACEMENT
This task covers:

INITIAL SETUP:
Equipment Condition
Materials/Parts Headlight beam selector switch removed
Four locknuts (Appendix G, Item 58.1) (para. 4-58).
Two lockwashers (Appendix G, Item 108)
a. Removal
1. Remove two nuts (1), capscrews (5), lockwashers (4), and clamps (3) from wiring harness (2),
insulation (9), and body (6). Discard lockwashers (4).
2. Remove four locknuts (12), capscrews (7), washers (8), retainer (10), and insulation (9) from floor (11).
b. Installation
1. Install insulation (9) and retainer (10) on floor (11) with four washers (8), capscrews (7), and
locknuts (12). Tighten capscrews (7) to 6 lb-ft (8 N•m).
2. Install wiring harness (2) and insulation (9) on body (6) with two clamps (3), capscrews (5),
lockwashers (4), and nuts (1).
FOLLOW-ON TASK: Install headlight beam selector switch (para. 4-58).
10-46 Change 1
TM 9-2320-280-20-3
10-27. RIGHT FRONT COWL INSULATION REPLACEMENT

This task covers:
lNITIAL SETUP
automotive (Appendix B, Item 1) Equipment Condition
Materials/Parts Heater assembly removed (para. 10-87).
Four locknuts (Appendix G, Item 58)
Remove four locknuts (6), capscrews (3), washers (2), retainer (1), and insulation (5) from floor (7).
1. Install insulation (5) and retainer (1) on floor (7) with four washers (2), capscrews (3), and locknuts (6).
Tighten capscrews (3) to 6 lb-ft (8 N-m).
2. Press insulation (5) into place on cowl (4).
FOLLOW-ON TASK: Install heater assembly (para. 10-87).
10-47
TM 9-2320-280-20-3
10-28. TUNNEL INTERIOR SIDE INSULATION REPLACEMENT

This task covers:
INITIAL SETUP:
General mechanic’s tool kit: s Left front cowl insulation removed (para. 10-26).
automotive (Appendix B, Item 1) ● Front floorboard removed (para. 11-154).
Manual References
TM 9-2320-280-24P
NOTE
Removal and installation procedures for all tunnel interior side
insulation are basically the same. This procedure covers the left
front insulation.
1. Remove two screws (4) from retaining rod (5) and cargo floor (6).
2. Remove two screws (2) from retaining rod (3) and cargo floor (6).
3. Remove three screws (1) and retaining rod (8) from tunnel (7) and cargo floor (6).
4. Remove two screws (9) from retaining rod (10) and tunnel (7).
5. Remove two screws (14), retainer (12), and insulation (11) from floor (13).
6. Remove retaining rods (3), (5), and (10) from insulation (11).
b. Installation
1. Install retaining rods (10), (3), and (5) on insulation (11).
2. Position insulation (11) into place against floor (13), tunnel (7), and cargo floor (6).
3. Install insulation (11) and retainer (12) on floor (13) with two screws (14).
4. Install retaining rod (10) on tunnel (7) with two screws (9).
5. Install retaining rod (8) on tunnel (7) with three screws (1).
6. Install retaining rod (3) on cargo floor (6) with two screws (2).
7. Install retaining rod (5) on cargo floor (6) with two screws (4).
10-48
TM 9-2320-280-20-3
10-28. TUNNEL INTERIOR SIDE INSULATION REPLACEMENT (Cont’d) I
FOLLOW-ON TASKS: . Install left front cowl insulation (para. 10-26).

● Install front floorboard (para. 11-154).
10-49
TM 9-2320-280-20-3
I 10-29. REAR SEAT FLOOR INSULATION REPLACEMENT

I
This task covers:
INITIAL SETUP:
Remove insulation (1) from floor (2).
I b. Installation
Install insulation (1) on floor (2).
10-50
TM 9-2320-280-20-3
I 10-30. RIGHT INNER COWL INSULATION PANEL REPLACEMENT

This task covers:
INITIAL SETUP
General mechanic’s tool kit TM 9-2320-280-10
Three locknuts (Appendix G, Item 58) Hood raised and secured (TM 9-2320-280-10).
Remove three locknuts (7), washers (4), capscrews (5), washers (4), retainer (3), insulation (2), and drain
hose clamp (6) from cowl (1). Discard locknuts (7).
Install drain hose clamp (6). insulation (2), and retainer (3) on cowl (1) with three washers (4), cap-
screws (5), washers (4), and locknuts (7).
FOLLOW-TASK: Lower and secure hood (TM 9-2320-280-10).
10-51
TM 9-2320-280-20-3
10-31. LEFT INNER COWL INSULATION PANEL REPLACEMENT

This task covers:
INITIAL SETUP:
Tools Personnel Required
General mechanic’s tool kit: One mechanic
automotive (Appendix B, Item 1) One assistant
Materials/Parts Manual References
Cotter pin (Appendix G, Item 17) TM 9-2320-280-10
Four locknuts (Appendix G, Item 58) TM 9-2320-280-24P
Three nut and lockwasher assemblies
(Appendix G, Item 144) Equipment Condition
O-ring seal (Appendix G, Item 162) Hood raised and secured (TM 9-2320-280-10).
1. Remove four locknuts (5), washers (3), capscrews (2), and washers (3) from harness clamp (4), brake
harness (8), retainer (1), and cowl (7). Discard locknuts (5).
2. Remove nut and lockwasher assembly (10), capscrew (12), and harness clamp (9) from body
harness (11), brake harness (8), and cowl (7). Discard nut and lockwasher assembly (10).
3. Remove nut and lockwasher assembly (15) and capscrew (13) from harness clamp (14) and
cowl (7) and disconnect body harness (11) from cowl (7). Discard nut and lockwasher assembly (15).
4. Remove upper insulation panel (6) by sliding up and out from between retainer (1) and cowl (7).
5. Remove nut and lockwasher assembly (19) and capscrew (17) from clamp (18) and cowl (7). Discard
nut and lockwasher (19).
6. Remove lower insulation panel (16) by sliding down between retainer (1) and cowl (7).
10-52
TM 9-2320-280-20-3
I 10-31. LEFT INNER COWL INSULATION PANEL REPLACEMENT (Cont’d)
10-53
TM 9-2320-280-20-3
10-31. LEFT INNER COWL INSULATION PANEL REPLACEMENT (Cont’d)

I
7. Remove four screws (8) from instrument cluster (3) and dash panel (7) and pull instrument
cluster (3) away for access to speedometer cable (2).
8. Remove speedometer cable (2) and O-ring seal (4) from speedometer (1). Discard O-ring seal (4).
9. Remove grommet (6) from cowl (5) and route speedometer cable (2) through cowl (5).
10. Remove cotter pin (14), washer (13), and accelerator cable (15) from linkage (12). Discard cotter
pin (14).
11. Pull retainer (9) clear of linkage (12) and remove retainer (9) from between splash shield (10) and
frame rail (11) by pulling forward and then down.
I b. Installation
1. Install retainer (9) by sliding up between splash shield (10) and frame rail (11) forward of cowl (5),
and then sliding back to mounting position on cowl (5).
2, Connect accelerator cable (15) to linkage (12) with washer (13) and cotter pin (14).
3. Route speedometer cable (2) through cowl (5). Install O-ring seal (4) into end of speedometer
cable (2) and connect speedometer cable (2) to speedometer (1).
4. Install instrument cluster (3) on dash panel (7) with four screws (8).
5. Install grommet (6) on speedometer cable (2) in cowl (5).
10-54
TM 9-2320-280-20-3
10-31. LEFT INNER COWL INSULATION PANEL REPLACEMENT (Cont’d)
10-55
TM 9-2320-280-20-3
10-31. LEFT INNER COWL lNSULATION PANEL REPLACEMENT (Cont’d)

6. Install lower insulation panel (14) by sliding up into position between retainer (2) and cowl (9).
7. Install clamp (19) on cowl (9) with capscrew (18) and nut and lockwasher assembly (20).
8. Install upper insulation panel (8) by sliding down into position between retainer (2) and cowl (9).
9. Install clamp (15) and body harness (17) on cowl (9) with screw (13) and nut and lockwasher
assembly (16).
10. Install clamp (11) on brake harness (7) and body harness (17) on cowl (9) with capscrew (12) and nut
and lockwasher assembly (10).
11. Install retainer (2) and brake harness (7) on cowl (9), ensuring rear ends of retainer (2) are inserted in
body holes (1), with harness clamp (5), four washers (4), capscrews (3), washers (4), and locknuts (6).
10-56
TM 9-2320-280-20-3
1 0 - 3 1 . LEFT INNER COWL INSULATION PANEL REPLACEMENT (Cont'd)
Change 1 10-56.1
TM 9-2320-280-20-3
1 0 - 3 1 . 1 . CARGO FLOOR ACCESS COVER MAINTENANCE (M1123)

This task covers:
b. Inspection
INITIAL SETUP:
General mechanic’s tool kit: • Mortar ammo container removed, if equipped
• Rear radio rack removed, if equipped
Materials/Parts (para. 12-144).
Four lockwashers (Appendix G, Item 114) • Troop/cargo winterization heater assembly
Adhesive sealant (Appendix C, Item 9.1) removed, if equipped (para. 12-95).
• Troop/cargo winterization front cargo floor cover
Manual References removed, if equipped (para. 12-110).
TM 9-2320-280-24P • S250 shelter removed, if equipped (para. 11-120).
• Ammo box tray (40 mm and 50 cal.) removed, if
equipped (para. 11-105).
• Soft top ambulance litter assembly removed, if
equipped (para. 11-124).
a. Removal
1. Remove four screws (2), lockwashers (3), washers (1), and cargo floor access cover (4) from cargo
floor (5). Discard lockwashers (3).
2. Remove adhesive sealant from cargo floor access cover (4) and cargo floor (5).
b. Inspection
Inspect for missing or damaged insert nuts (6). Replace missing or damaged insert nuts (6) (para. 10-66).
c. Installation
1. Apply adhesive sealant to cargo floor (5) and cargo floor access cover (4).
2. Install cargo floor access cover (4) on cargo floor (5) with four washers (1), lockwashers (3), and
screws (2).
10-56.2 Change 1
TM 9-2320-280-20-3
1 0 - 3 1 . 1 . CARGO FLOOR ACCESS COVER MAINTENANCE (M1123) (C

ont’d)
FOLLOW-ON TASKS: • Install soft top ambulance litter, if removed (para. 11-124).
• Install ammo box tray (40 mm and 50 cal.), if removed (para. 11-105).
• Install S250 shelter, if removed (para. 11-120).
• Install troop/cargo winterization front floor cover, if removed (para. 12-110).
• Install troop/cargo winterization heater assembly, if removed (para. 12-95).
• Install rear radio rack, if removed (para. 12-144).
• Install mortar ammo container, if removed (para. 12-149).
Change 1 10-57
TM 9-2320-280-20-3
10-32. DRIVER’S SEAT FRAME REPLACEMENT

This task covers:
INITIAL SETUP
M966, M996, M997, M998, M1025, M1026, Sixteen locknuts (Appendix G, Item 65)
M1035, M1036, M1037, M1038, M1042,
M1043, M1044, M1045, M1046, M1097 Manual References
TM 9-2320-280-24P
Tools
General mechanic’s tool kit: Equipment Condition
automotive (Appendix B, Item 1) Driver’s seat and seat back cushions removed
(para. 10-33).
NOTE
Ensure P/N 12338503-1 is used for replacement of driver’s seat
frame on vehicles equipped with three-point seatbelt.
1. Place driver’s seat (1) in full forward position.

2. Remove sixteen locknuts (7), washers (4), capscrews (3), washers (4), and four adjuster brackets (5)
from driver’s seat bracket (8). Discard locknuts (7).
3. Lift up on driver’s seat frame (2) and remove from driver’s seat bracket (8).
4. Remove two spring pins (10) from inside retainers (9) and two rod and bushing assemblies (6) in seat
frame (2) by sliding rod and bushing assemblies out from seat frame (2).
1. Install two rod and bushing assemblies (6) on seat frame (2) with two inside retainers (9) and spring
pins (10).
2. Install driver’s seat frame (2) on driver’s seat bracket (8) with four adjuster brackets (5), sixteen
washers (4), capscrews (3), washers (4), and locknuts (7). Tighten capscrews (3) to 21 lb-ft (29 N=m).
3. Adjust driver’s seat (1) for desired position.
10-58
TM 9-2320-280-20-3
I 10-32. DRIVER’S SEAT FRAME REPLACEMENT (Cont’d) I
FOLLOW-ON TASK: Install driver’s seat and seat back cushions (para. 10-33).
10-59
TM 9-2320-280-20-3
10-33. DRIVER’S SEAT AND SEAT BACK CUSHIONS REPLACEMENT

This task covers:
INITIAL SETUP
M966, M996, M997, M998, M1025, M1026, Four hitch pins (Appendix G, Item 53)
M1035, M1036, M1037, M1038, M1042,
TM 9-2320-280-24P
Tools
1. Remove four hitch pins (2) from seat holddown pins (5). Discard hitch pins (2).
2. Remove four seat back cushion flaps (4) from holddown pins (5) and remove seat back cushion (3)
from seat frame (7).
3. Remove two seat cushion straps (6) from holddown pins (5).
4. Remove front retainer strip (8) from seat frame (7) and remove seat cushion (1).
I b. Installation
I
1. Install seat cushion (1) on seat frame (7) and install retainer strip (8) on seat frame (7).
2. Install two seat cushion straps (6) on holddown pins (5).
3. Install seat back cushion (3) on seat frame (7) and four flaps (4) on holddown pins (5).
4. Install four hitch pins (2) on holddown pins (5).
1O-6O
TM 9-2320-280-20-3
10-34. COMPANION SEAT BACK REPLACEMENT

This task covers:
INITIAL SETUP
M966, M996, M997, M998, M1025, M1026, Four locknuts (Appendix G, Item 65)
M1035, M1036, M1037, M1038, M1042,
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) Companion seat and battery box cover removed
(para. 10-35).
a. Removal
1. Remove four locknuts (7), washers (5), capscrews (4), washers (5), and seat back (2) from body (6).
2. Remove four nuts (1), washers (8), and seat back cushion (3) from seat back (2).
b. Installation
1. Install seat back cushion (3) on seat back (2) with four washers (8) and nuts (1). Tighten nuts (1) to
15 lb-ft (20 N.m).
2. Install seat back (2) on body (6) with four washers (5), capecrews (4), washers (5), and locknuts (7).
Tighten capscrews (4) to 21 lb-ft (29 Nom).
FOLLOW-ON TASK: Install companion seat and battery box cover (para. 10-35).
10-61
TM 9-2320-280-20-3
10-35. COMPANION SEAT AND BATTERY BOX COVER REPLACEMENT

This task covers:
INITIAL SETUP
Applicable Models Tools
M966, M996, M997, M998, M1025, M1026, _General mechanic’s tools kit:
M1035, M1036, M1037, M1038, M1042, automotive (Appendix B, Item 1)
M1043, M1044, M1045, M1046, M1097
Manual References
TM 9-2320-280-24P
1. Release two latches (3) from companion seat and battery box cover (1).
2. Lift up and pull forward on companion seat and battery box cover (1) and remove from battery
box (2).
b. Installation
Install companion seat and battery box cover (1) on battery box (2) with two latches (3).
10-62
TM 9-2320-280-20-3
10-36. BATTERY BOX COVER LATCH REPLACEMENT

This task covers:
INITIAL SETUP:
M966, M996, M997, M998, M1025, M1026, Two rivets (Appendix G, Item 181)
M1035, M1036, M1037, M1038, M1042, Two rivets (Appendix G, Item 182)
Tools TM 9-2320-280-24P
Batteries removed (para. 4-79).
NOTE
For instruction on replacement of rivets, refer to para. 10-66.
I a Removal
1. Remove two rivets (1) and striker latch (2) from battery box cover (3).
2. Remove two rivets (6) and tension latch (5) from battery box (4).
1. Install tension latch (5) on battery box (4) with two rivets (6).
2. Install striker latch (2) on battery box cover (3) with two rivets (1).
FOLLOW-ON TASK: Install batteries (para. 4-79).
10-63
TM 9-2320-280-20-3
10-37. COMPANION SEAT AND SEAT BACK CUSHIONS REPLACEMENT

This task covers:
INITIAL SETUP
M966, M996, M997, M998, M1025, M1026, TM 9-2320-280-24P
M1035, M1036, M1037, M1038, M1042,
M1043, M1044, M1045, M1046, M1097 Equipment Condition
Companion seat and battery box cover removed
Tools (para. 10-35).
a. Removal
1. Remove four nuts (7) and cushion (5) from battery box cover (6).
2. Remove four nuts (1), washers (2), and cushion (4) from seat back (3).
b. Installation
1. Install cushion (4) on seat back (3) with four washers (2) and nuts (1). Tighten nuts (1) to 15 lb-ft
(20 N.m).
2. Install cushion (5) on battery box cover (6) with four nuts (7). Tighten nuts (7) to 15 lb-ft (20 N.m).
FOLLOW-ON TASK: Install companion seat and battery box cover (para. 10-35).
10-64
TM 9-2320-280-20-3
I 10-38. DRIVER’S SEAT ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP
M966A1, M996A1, M997A1, M997A2, Four lockwashers (Appendix G, Item 140)
M998A1, M1025A1, M1025A2, M1026A1,
M1035A1, M1035A2, M1038A1, M1043A1, Manual References
M1043A2, M1044A1, M1045A1, M1045A2, TM 9-2320-280-24P
M1046A1, M1097A1, M1097A2
Tools
1. Spread cover (6) to allow access to capscrews (2).

2. Remove four capscrews (2), lockwashers (3), spacers (4), cover (6), and seat assembly (1) from
floor (5).
b. Installation
Install cover (6) and seat assembly (1) on floor (5) with four spacers (4), lockwashers (3), and capscrews (2).
10-65
TM 9-2320-280-20-3
10-39. DRIVER’S SEAT ASSEMBLY MAINTENANCE

This task covers:
a. Disassembly b. Assembly
INITIAL SETUP:
M966A1, M996A1, M997A1, M997A2, Twelve lockwashers (Appendix G, Item 140)
M998A1, M1025A1, M1025A2, M1026A1,
M1035A1, M1035A2, M1038A1, M1043A1 Manual References
M1043A2, M1044A1, M1045A1, M1045A2, TM 9-2320-280-24P
M1046A1, M1097A1, M1097A2
Equipment Condition
Tools Driver’s seat assembly removed (para. 10-38).
NOTE
Slide seat back and forth to gain access to slide set hardware.
1. Remove four nuts (12), loclwashers (11), capscrews (9), height adjuster (13), and cover (14) from
slide set (10). Discard lockwashers (11).
2. Remove four nuts (8), lockwashers (16), and seat (2) from riser (6). Discard lockwashers (16).
3. Remove four nuts (3), lockwashers (4), capscrews (15), riser (6), and tray (5) from slide set (10). Discard
lockwashers (4).
4. Remove two nuts (17), capscrews (19), loop (18), and strap (1) from riser (6).
5. Inspect velcro strip (7) on riser (6) for damage and replace if damaged.
b. Assembly
1. Install strap (1) and loop (18) on riser (6) with two capscrews (19) and nuts (17).
2. Install tray (5) and riser (6) on slide set (10) with four capscrews (15), lockwashers (4), and nuts (3).
3. Install seat (2) on riser (6) with four lockwashere (16) and nuts (8).
4. Install height adjuster (13) and cover (14) on slide set (10) with four capscrews (9), lockwashers (11),
and nuts (12).
10-66
TM 9-2320-280-20-3
10-39. DRIVER’S SEAT ASSEMBLY MAINTENANCE (Cont’d)
FOLLOW-ON TASK: Install driver’s seat assembly (para. 10-38).
10-67
TM 9-2320-280-20-3
10-40. BATTERY BOX COVER CATCH REPLACEMENT

This task covers:
INITIAL SETUP:
M966A1, M996A1, M997A1, M997A2, Two rivets (Appendix G, Item 181)
M998A1, M1025A1, M1025A2, M1026A1, Two rivets (Appendix G, Item 182)
M1035A1, M1035A2, M1038A1, M1043A1,
M1046A1, M1097A1, M1097A2 TM 9-2320-280-24P
Equipment Condition
General mechanic’s tool kit Batteries removed (para. 4-79).
NOTE
For instruction on replacement of riveta, refer to para. 10-66.
1. Remove two rivets (1) and striker catch (2) from battery box cover (3) and bracket (7).
2. Remove two rivets (6) and clamping catch (5) from battery box (4).
1. Install clamping catch (5) on battery box (4) with two rivets (6).
2. Install striker catch (2) on battery box cover (3) and bracket (7) with two rivets (1).
FOLLOW-ON TASK: Install batteries (para. 4-79).
10-68
TM 9-2320-280-20-3
10-41. COMPANION SEAT ASSEMBLY AND BATTERY BOX COVER REPLACEMENT

This task covers:
INITIAL SETUP:
M966A1, M996A1, M997A1, M997A2, General mechanic’s tool kit:
M998A1, M1025A1, M1025A2, M1026A1, automotive (Appendix B, Item 1)
M1035A1, M1035A2, M1038A1, M1043A1,
M1046A1, M1097A1, M1097A2 TM 9-2320-280-24P
1. Release two latches (3) from companion seat and battery box cover (1).
2. Lift up and pull forward on companion seat and battery box cover (1) and remove from battery box (2).
Install companion seat and battery box cover (1) on battery box (2) with two latches (3)
10-69
10-42. COMPANION SEAT ASSEMBLY MAINTENANCE
I
This task covers:

M966A1, M996A1, M997A1, M997A2, Four lockwashers (Appendix G, Item 140)
M998A1, M1025A1, M1025A2, M1026A1,
M1043A2, M1044A1, M1045A1, M1045A2, TM 9-2320-280-24P
M1046A1, M1097A1, M1097A2
Equipment Condition
Companion seat assembly and battery box cover
General mechanic’s tool kit: removed (para. 10-41).
I a. Disassembly
Remove four nuts (6), lockwashers (5), spacers (4), seat (1), and plate (2) from battery box cover (3).
b. Assembly
Install plate (2) and seat (1) on battery box cover (3) with four spacers (4), lockwashers (5), and nuts (6).
Tighten nuts (6) to 15 lb-ft (20 Nom).
FOLLOW-ON TASK: Install companion seat assembly and battery box cover (para. 10-41).
10-70
TM 9-2320-280-20-3
10-43. PASSENGER SEAT AND STORAGE COMPARTMENT COVER REPLACEMENT

This task covers:
INITIAL SETUP:
All except M996, M996A1, M997, M997A1, TM 9-2320-280-24P
M997A2, M1037, M1042
Tools
Release two latches (3) and remove passenger seat and storage compartment cover (1) from storage
compartment box (2).
Install passenger seat and storage compartment cover (1) on storage compartment box (2) with two
latches (3).
10-71
TM 9-2320-280-20-3
10-44. PASSENGER SEAT AND STORAGE COMPARTMENT LATCH REPLACEMENT

This task covers:
INITIAL SETUP
M997A2, M1037, M1042
Equipment Condition
Tools Passenger seat and storage compartment cover
General mechanic’s tool kit: removed (para. 10-43).
Materials/Parts
Two rivets (Appendix G, Item 181)
NOTE
For instructions on replacement of rivets, refer to para. 10-66.
1. Remove two rivets (1) and striker latch (2) from passenger seat and storage compartment cover (3).
2. Remove two rivets (6) and tension latch (5) from storage compartment box (4).
b. Installation
1. Install tension latch (5) on storage compartment box (4) with two rivets (6).
2. Install striker latch (2) on passenger seat and storage compartment cover (3) with two rivets (1).
FOLLOW-ON TASK: Install passenger seat and storage compartment cover (para. 10-43).
10-72
TM 9-2320-280-20-3
10-45. PASSENGER SEAT BACK REPLACEMENT I

This task covers:
INITIAL SETUP
M997A2, M1037, M1042
Tools
a. Removal
Remove two locking pins (1) and passenger seat back (2) from body (3).
b. Installation
Install passenger seat back (2) on body (3) with two locking pins (1).
10-73
TM 9-2320-280-20-3
10-46. PASSENGER SEAT AND SEAT BACK CUSHIONS REPLACEMENT

This task covers:
INITIAL SETUP:
M997A2, M1037, M1042
Equipment Condition
Tools ● Passenger seat and storage compartment cover
General mechanic’s tool kit removed (para. 10-43).
automotive (Appendix B, Item 1) ● Passenger seat back removed (para. 10-45).
a. Removal
1. Remove four nuts (7) and seat cushion (5) from storage compartment cover (6).
2. Remove four nuts (3), eight spacers (4), and seat back cushion (1) from seat back (2).
b. Installation
1. Install seat back cushion (1) on seat back (2) with eight spacers (4) and four nuts (3). Tighten nuts (3)
to 15 lb-ft (20 N.m).
2. Install seat cushion (5) on storage compartment cover (6) with four nuts (7). Tighten nuts (7) to
15 lb-ft (20 N.m).
FOLLOW-ON TASKS: . Install passenger seat and storage compartment cover (para. 10-43).
s Install passenger seat back (para. 10-45).
10-74
TM 9-2320-280-20-3
I 10-47. SEATBELT ASSEMBLY REPLACEMENT

I
This task covers:
INITIAL SETUP:
● Passenger seat back removed, rear seatbelt only (para. 10-45).
● Companion seat and battery box cover removed,
companion seatbelt only (para- 10-35).
Manual References
TM 9-2320-280-24P Seatbelts are to be replaced as a set.
WARNING
Seatbelts are to be replaced as a set. Failure to do this may cause
NOTE
● This procedure applies to all vehicles with serial numbers USBL
Eff. 99,999 and below.
● All seatbelt removal and installation procedures are basically
the same. This procedure covers the driver’s seatbelt.
1. Remove anchor bolt (8), buckle assembly (7), and washer (6) from bracket (5).
2. Remove anchor bolt (4), connector assembly (3), and washer (2) from body (1).
I b. Installation
1. Install washer (2) and connector assembly (3) on body (1) with anchor bolt (4). Tighten anchor bolt (4)
to 35-40 lb-ft (47-54 Nom).
2. Install washer (6) and buckle assembly (7) on bracket (5) with anchor bolt (8). Tighten anchor bolt (8)
to 35-40 lb-ft (47-54 Nom).
FOLLOW-ON TASKS: . Install passenger seat back, rear seatbelt only (Pam. 10-45).
● Install companion seal battery box cover, companion seatbelt only (para. 10-35).
10-75
TM 9-2320-280-20-3
10-48. THREE POINT SEATBELT MAINTENANCE

This task covers:
a. Front Seatbelt Removal d. Rear Seatbelt Removal
b. Front Seatbelt Bracket Inspection e. Rear Seatbelt Bracket Inspection
c. Front Seatbelt Installation f. Rear Seatbelt Installation
INITIAL SETUP:
Applicable Models Equipment Condition
All models except M996, M996A1, M997, l Passenger seat back removed, rear seatbelt only
M997A1, M997A2 (para. 10-45).
l Companion seat and battery box cover removed,
Tools companion seatbelt only (para. 10-35).
General mechanic’s tool kit: l Four-man soft top curtain removed, rear seatbelt
only (TM 9-2320-280-10).
automotive (Appendix B, Item 1) l Rear doors removed, armament vehicles only
Manual References (para. 11-2).
TM 9-2320-280-10 General Safety Instructions
TM 9-2320-280-24P Seatbelts are to be replaced as a set.
WARNING
NOTE
Left and right seatbelt maintenance procedures are basically the
same. This procedure covers the left seatbelt.
a. Front Seatbelt Removal

1. Remove capscrew (26), buckle assembly (25), and washer (24) from body (23).
2. Remove capscrew (22), connector assembly (21), and washer (20) from bracket (19).
NOTE
Steps 3 and 4 apply to all armament vehicles.
3. Remove two screws (7) and washers (8) from “B” pillar cover (12) and roof (6).
4. Remove two screws (14), washers (13), and “B” pillar cover (12) from “B” pillar (11).
NOTE
Step 5 applies to armament vehicles with serial numbers USBL
Eff. 100,000 through 134,152 only.
5. Remove nut (9), washer (10), capscrew (1), “D” ring (2), washer (3), and bracket half (4) from
“B” pillar (11).
NOTE
Step 6 applies to armament vehicles with serial numbers USBL Eff.
134,153 and above only. Steps 7 and 8 apply to all other vehicles.
6. Remove capscrew (1), “D” ring (2), washer (3), and bracket halves (4) and (5) from “B” pillar (11).
7. Remove capscrew (15), “D” ring (16), and washer (17) from upper bracket (18).
8. Remove capscrew (27), washer (28), and retractor (29) from lower bracket (30).
10-76
TM 9-2320-280-20-3
10-48. THREE POINT SEATBELT MAINTENANCE (Cont’d)
10-77
TM 9-2320-280-20-3
10-48. THREE POINT SEATBELT MAINTENANCE (Cont’d)
b. Front Seatbelt Bracket Inspection

NOTE
Step 1 applies to armament vehicles only. Step 2 applies to all other vehicles.
1. Inspect bracket halves (4) and (5) for bends, or cracls. Replace if broken, bent or cracked.
2. Inspect upper bracket (18) for breaks, bends, or cracks. Replace if broken, bent, or cracked, refer to
para. 10-49.
3. Inspect lower bracket (30) for breaks, bends, or cracks. Replace if broken, bent, or cracked, refer to
para. 10-49.
c. Front Seatbelt Installation

1. Install retractor (29) on lower bracket (30) with washer (28) and capscrew (27). Tighten capscrew (27)
to 43-60 lb-ft (58-81 N~m).
NOTE
Eff. 134,153 and above only.
2. Install “D” ring (2) and bracket halves (4) and (5) to “B” pillar (11) with washer (3) and capscrew (1).
NOTE
Eff. 100,000 through 134,152 only.
3. Install bracket half (4), washer (3), and “D” ring (2) on “B” pillar (11) with capscrew (1), washer (10),
and nut (9). Tighten nut (9) to 35-40 lb-ft (47-54 N.m).
NOTE
Steps 4 and 5 apply to all armament vehicles.
4. Install “B” pillar cover (12) on roof (6) with two washers (8) and screws (7).
5. Install “B” pillar cover (12) on “B” pillar (11) with two washers (13) and screws (14).
6. Install washer (17) and “D” ring (16) on upper bracket (18) with capscrew (15). Tighten
capscrew (15) to 35-40 lb-ft (47-54 N~m).
7. Install washer (20) and connector assembly (21) on bracket (19) with capscrew (22). Tighten
capscrew (22) to 35-40 lb-ft (47-54 N.m).
8. Install washer (24) and buckle assembly (25) on body (23) with capscrew (26). Tighten capscrew (26)
to 35-40 lb-ft. (47-54 N.m).
10-78
TM 9-2320-280-20-3
10-48. THREE POINT SEATBELT MAINTENANCE (Cont’d) I
10-79
TM 9-2320-280-20-3
I 10-48. THREE POINT SEATBELT MAINTENANCE (Cont’d)

I
I d. Rear Seatbelt Removal
NOTE
same. This procedure covers the right seatbelt.
1. Remove capscrew (22), buckle assembly (25), and washer (23) from body (24).
2. Remove capscrew (21), connector assembly (26), and washer (20) from bracket (27).
NOTE
Steps 3 and 4 apply to armament vehicles only. Steps 5 and 6
apply to all other vehicles.
3. Remove capscrew (4), “D” ring (5), and washer (6) from bracket (7).
4. Remove capscrew (1), washer (2), and retractor (3) from bracket (7).
5. Remove nut (17), washer (16), capscrew (12), “D” ring (13), and washer (14) from bracket (11).
6. Remove nut (18), washer (19), capscrew (8), washer (9), and retractor (10) from bracket (11).
e. Rear Seatbelt Bracket Inspection
NOTE
Rear seatbelt bracket inspection applies to all vehicles except
armament vehicles.
1. Inspect bracket (11) for breaks, bends, or cracks. Replace if broken, bent, or cracked (refer to
para. 10-49).
2. Inspect turnbutton (15) for bends, corrosion, or damage. Replace if bent, corroded, or damaged (refer
to para. 10-66 for rivet removal).
I f. Rear Seatbelt Installation
NOTE
Steps 1 and 2 apply to armament vehicles only. Steps 3 and 4
apply to all other vehicles.
1. Install retractor (3) on bracket (7) with washer (2) and capscrew (1). Tighten capscrew (1) to
35-40 lb-ft (47-54 N.m).
2. Install washer (6) and “D” ring (5) on bracket (7) with capscrew (4). Tighten capscrew (4) to
35-40 Ib-ft (47-54 N.m).
3. Install retractor (10) on bracket (11) with washer (9), capscrew (8), washer (19), and nut (18). Tighten
capscrew (8) to 43-60 lb-ft (58-81 Nom).
4. Install washer (14) and ‘n” ring (13) on bracket (11) with capscrew (12), washer (16), and nut (17).
Tighten nut (17) to 35-40 lb-ft (47-54 N.m).
5. Install washer (20) and connector assembly (26) on bracket (27) with capscrew (21). Tighten
capscrew (21) to 35-40 lb-ft (47-54 N.m).
6. Install washer (23) and buckle assembly (25) on body (24) with capscrew (22). Tighten capscrew (22)
to 35-40 lb-ft (47-54 N.m).
10-80
TM 9-2320-280-20-3
1 0 - 4 8 . THREE POINT SEAT B E LT MAINTENANCE (Cont'd)
ARMAMENT VEHICLE
FOLLOW-ON TASKS: • Install passenger seat back, rear seatbelt only (para. 10-45).
• Install companion seat and battery box cover, companion seatbelt only (para. 10-35).
• Install four-man soft top curtain, rear seatbelt only (TM 9-2320-280-10).
• Install rear doors, armament vehicles only (para. 11-2).
Change 1 10-80.1
TM 9-2320-280-20-3
1 0 - 4 8 . 1 . THREE POINT SEAT B E LT MAINTENANCE (M996, M996A1, M997, M997A1,

AND M997A2)
This task covers:
a. Seatbelt Removal c. Seatbelt Installation
b. Seatbelt Bracket Inspection
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 TM 9-2320-280-24P
General mechanic’s tool kit: Companion seat and battery box cover removed,
automotive (Appendix B, Item 1) (companion seatbelt only) (para. 10-35).
WARNING
NOTE
same. This procedure covers the left seatbelt.
a. Seatbelt Removal
1. Remove capscrew (4), buckle assembly (3), and washer (2) from bracket (1).
2. Remove capscrew (8), connector assembly (5), and washer (7) from body (6).
3. Remove capscrew (9), D-ring (11), and washer (10) from bulkhead (12).
4. Remove capscrew (16), retractor (15), and washer (14) from bracket (13).
b. Seatbelt Bracket Inspection
Inspect brackets (1) and (13) for breaks, bends, or cracks. Replace if broken, bent, or cracked
(para. 10-49.1).
c. Seatbelt Installation
1. Install washer (14) and retractor (15) on bracket (13) with capscrew (16). Tighten capscrew (16) to
35-40 lb-ft (47-54 N•m).
2. Install washer (10) and D-ring (11) on bulkhead (12) with capscrew (9). Tighten capscrew (9) to
35-40 lb-ft (47-54 N•m).
3. Install washer (7) and connector assembly (5) on body (6) with capscrew (8). Tighten capscrew (8) to
35-40 lb-ft (47-54 N•m).
4. Install washer (2) and buckle assembly (3) on bracket (1) with capscrew (4). Tighten capscrew (4) to
35-40 lb-ft (47-54 N•m).
10-80.2 Change 1
TM 9-2320-280-20-3
1 0 - 4 8 . 1 . THREE POINT SEAT B E LT MAINTENANCE (M996, M996A1, M997, M997A1,

AND M997A2) (C o n t ’ d )
FOLLOW-ON TASK: Install companion seat and battery box cover (companion seatbelt only) (para. 10-35).
Change 1 10-81
TM 9-2320-280-20-3
10-49. THREE POINT SEATBELT BRACKETS REPLACEMENT

This task covers:
a. Front Seatbelt Bracket Removal c. Rear Seatbelt Bracket Removal
b. Front Seatbelt Bracket Installation d. Rear Seatbelt Bracket Installation
INITIAL SETUP:
All models except M996, M996A1, M997, TM 9-2320-280-24P
M997A1, M997A2
Equipment Condition
Tools Three point seatbelt removed (para. 10-48).
NOTE
Left and right seatbelt brackets replacement procedures are
basically the same. This procedure covers the left seatbelt bracket.
a. Front Seatbelt Bracket Removal
1. Remove four capscrews (3), washers (2), and upper bracket (1) from “B” pillar (4).
2. Remove four capscrews (6), washers (5), and lower bracket (7) from “B” pillar (4).
b. Front seatbelt Bracket Installation
1. Install lower bracket (7) on “B” pillar (4) with four washers (5) and capscrews (6). Tighten capscrews (6)
to 15-21 lb-n (20-29 N.m).
2. Install upper bracket (1) on “B” pillar (4) with four washers (2) and capscrews (3). Tighten capscrews (3)
to 15-21 lb-ft (20-29 N.m).
c. Rear Seatbelt Bracket Removal
NOTE
Left and right seatbelt brackets replacement procedures are
basically the same. This procedure covers the right seatbelt bracket.
1. Remove two nuts (15), washers (14), capscrews (12), and washers (13) from bracket (10) and
wheelhouse (16).
2. Remove two nuts (18), washers (17), capscrews (9), washers (8), and bracket (10) from wheelhouse (16).
3. Inspect turnbutton (11) for bends, corrosion, or damage. Replace if damaged, refer to para. 10-66 for
rivet removal.
d. Rear seatbelt Bracket installation

1. Install bracket (10) on wheelhouse (16) with two washers (8), capscrews (9), washers (17), and nuts (18).
Tighten capscrews (9) to 43-60 Ib-ft (58-81 N.m).
2. Secure bracket (10) to wheelhouse (16) with two washers (13), capscrews (12), washers (14), and
nuts (15). Tighten capscrews (12) to 43-60 lb-ft (58-81 Nom).
10-82
TM 9-2320-280-20-3
1 0 - 4 9 . THREE POINT SEAT B E LT BRACKETS REPLACEMENT (Cont'd)
FOLLOW-ON TASK: Install three point seatbelt (para. 10-48).
Change 1 10-82.1
TM 9-2320-280-20-3
1 0 - 4 9 . 1 . THREE POINT SEAT B E LT BRACKETS REPLACEMENT (M996, M996A1, M997,

M997A1, AND M997A2)
This task covers:
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 TM 9-2320-280-24P
General mechanic’s tool kit: Three point seatbelt removed (para. 10-48.1).
NOT E
Left and right seatbelt bracket replacement procedures are
basically the same. This procedure covers the left seatbelt bracket.
a. Removal
1. Remove two nuts (6), capscrews (4) and (5), four washers (3), and bracket (2) from body (7) and
“B” pillar (1).
2. Remove capscrew (11), washer (10), and bracket (8) from mount (9).
b. Installation
1. Install bracket (8) on mount (9) with washer (10) and capscrew (11). Tighten capscrew (11) to
90-95 lb-ft (122-129 N•m).
2. Install bracket (2) on body (7) and “B” pillar (1) with four washers (3), two capscrews (4) and (5), and
nuts (6). Tighten capscrews (4) to 9-11 lb-ft (12-15 N•m) and capscrews (5) to 20-22 lb-ft (27-30 N•m).
10-82.2 Change 1
TM 9-2320-280-20-3
1 0 - 4 9 . 1 . THREE POINT SEAT B E LT BRACKETS REPLACEMENT (M996, M996A1, M997,

M997A1, AND M997A2) (Co n t ’ d )
FOLLOW-ON TASK: Install three point seatbelt (para. 10-48.1).
Change 1 10-83
TM 9-2320-280-20-3
10-50. PIONEER TOOL STOWAGE TRAY MAINTENANCE

This task covers:
INITIAL SETUP
Six lockwashere (Appendix G, Item 110) Pioneer tool stowage tray removed
Eight lockwashers (Appendix G, Item 116) (TM 9-2320-280-10).
NOTE
● The procedures for disassembly and assembly of pioneer tool
stowage trays for all vehicles are basically the same. The tray for
M1037 and M1042 has tension latches mounted on angle
brackets.
● Note position of straps for assembly.
1. Remove retainer (1) from pioneer tool stowage tray (14).

2. Remove eight nuts (5), lockwashers (4), screws (2), four footman loops (3), and two strap
assemblies (6) from pioneer tool stowage tray (14). Discard lockwashers (4).
3. Remove two nuts (11), lockwashers (10), and two bumpers (13) from tool stowage tray (14). Discard
lockwashers (10).
4. Remove four nuts (9), lockwashers (8), capscrews (12), and two latches (7) from pioneer tool stowage
tray (14). Discard lockwashers (8).
1. Install two latches (7) on pioneer tool stowage tray (14) with four capscrews (12), lockwashers (8),
and nuts (9). Tighten nuts (9) to 16-30 lb-in. (2-3 Nom).
2. Install two bumpers (13) on pioneer tool stowage tray (14) with lockwashers (10) and nuts (11).
3. Install two strap assemblies (6) on pioneer tool stowage tray (14) with four footman loops (3), eight
screws (2), lockwashers (4), and nuts (5). Tighten nuts (5) to 16-30 lb-in. (2-3 N-m).
4. Install retainer (1) on pioneer tool stowage tray (14).
10-84
TM 9-2320-280-20-3
I 10-50. PIONEER TOOL STOWAGE TRAY MAINTENANCE (Cont’d)
FOLLOW-ON TASK: Install pioneer tool stowage tray (TM 9-2320-280-10).
10-58
TM 9-2320-280-20-3
10-51. PIONEER TOOL STOWAGE TRAY MOUNTING BRACKET REPLACEMENT

This task covers:
INITIAL SETUP
General mechanic’s tool kit: Pioneer tool stowage tray removed
automotive (Appendix B, Item 1) (TM 9-2320-280-10).
Manual References
TM 9-2320-280-10
TM 9-2320-280-24P
Remove two capscrews (2), washers (3), and mounting bracket (1) from rear crossmember (4).
b. Installation
I
Install bracket (1) on rear crossmember (4) with two washers (3) and capscrews (2). Tighten capscrews (2)
to 37 lb-ft (50 N.m).
10-86
TM 9-2320-280-20-3
10-52. PIONEER TOOL STOWAGE TRAY LATCH STRIKER REPLACEMENT

This task covers:
INITIAL SETUP
Two lockwashers (Appendix G, Item 113) Pioneer tool stowage tray removed
(TM 9-2320-280-10).
Remove two nuts (5), lockwashers (4), capscrews (3), and tool tray latch striker (2) from frame (1).
Install tool tray latch striker (2) on frame (1) with two capscrews (3), lockwashers (4), and nuts (5).
Tighten nuts (5) to 16-30 lb-in. (2-3 N.m).
10-87
TM 9-2320-280-20-3
10-53. CARGO BULKHEAD REPLACEMENT

This task covers:
lNITIAL SETUP:
M998, M998A1, M1038, M1038A1, M1097, Four lockwaahers (Appendix G, Item 123)
M1097A1, M1097A2
ManuaI References
Tools TM 9-2320-280-24P
1. Remove two capscrews (7), lockwashers (8), washers (9), and cargo bulkhead bracket (10) from
cargo floor (11). Discard lockwashers (8).
2. Remove two nuts (1), lockwashers (2), washers (3), capscrews (5), and washers (3) from cargo
bulkhead (6) and “B“ pillar (4). Discard lockwashers (2).
3. Remove cargo bulkhead (6) from vehicle.
4. Inspect anti-noise pads (12) for damage. Replace if damaged.
1. Install cargo bulkhead (6) on cargo floor (11).

2. Install cargo bulkhead (6) on “B” pillar (4) with two washers (3), capscrews (5), washers (3),
3. Install cargo bulkhead bracket (10) on cargo floor (11) with two washers (9), lockwashers (8), and
capscrews (7). Tighten capscrews (7) to 65 lb-ft (88 N.m).
4. Tighten nuts (1) to 15 lb-ft (20 N.m).
10-88
TM 9-2320-280-20-3
10-54. CARGO BULKHEAD MOUNTING BRACKETS REPLACEMENT

This task covers:
lNITIAL SETUP:
M998, M998A1, M1038, M1038A1, M1097, TM 9-2320-280-24P
M1097A1, M1097A2
Equipment Condition
Tools Cargo bulkhead removed (para. 10-53).
1. Remove nut (6), washer (7), capscrew (10), washer (7), cargo bracket (9), and tiedown (8) from cargo
floor (5).
NOTE
Note position of latch on “B” pillar for installation.
2. Remove two capscrews (4), latch (3), and latch retainer (2) from “B” pillar (1).
1. Install latch (3) and latch retainer (2) on “B” pillar (1) with two capscrews (4). Tighten capscrews (4)
to 6 lb-ft (8 N.m)
2. Install tiedovvn (8) and bracket (9) on cargo floor (5) with washer (7), capscrew (10), washer (7), and
nut (6). Tighten capscrews (10) to 26 lb-ft (35 Nom).
FOLLOW-ON TASK: Install cargo bulkhead (para. 10-53).
10-89
TM 9-2320-280-20-3
10-55. CARGO BARRIER EXTENSION MAINTENANCE 1

This task covers:
a Removal c. Assembly
INITIAL SETUP
Materials/Parts
Applicable Models
Eight locknuts (Appendix G, Item 76)
M998, M998A1, M1038, M1038A1, M1097,
M1097A1, M1097A2 Manual References
Tools TM 9-2320-280-24P
Remove quick release pin (12) from post assembly (4) and remove cargo barrier extension (5) from cargo
bulkhead (13).
1. Remove screw (6) and lanyard (7) from post assembly (4).
2. Remove twenty-four screws (1), nut and washer assemblies (3), and three backboards (2) from four
post assemblies (4).
3. Remove eight locknuts (11), washers (9), capscrews (8), washers (9), and four mounting brackets (10)
from cargo bulkhead (13). Discard locknuts (11).
c. Assembly
1. Install lanyard (7) on post assembly (4) with screw (6).

2. Install three backboards (2) on post four assemblies (4) with twenty-four screws (1) and nut and
washer assemblies (3).
3. Install four mounting brackets (10) on cargo bulkhead (13) with eight washers (9), capscrews (8),
NOTE
When installing cargo barrier extension, ensure side rack pins on
post assemblies slide into holes of cargo bulkhead.
Install cargo barrier extension (5) to cargo bulkhead (13) with quick release pin (12).
10-90
TM 9-2320-280-20-3
I 10-55. CARGO BARRIER EXTENSION MAINTENANCE (Cont’d)
10-91
TM 9-2320-280-20-3
10-56. CARGO TIEDOWN REPLACEMENT

This task covers:
INITIAL SETUP:
All except M996, M996A1, M997, M997A1, Locknut (Appendix G, Item 70)
M997A2, M1037, M1042
Manual References
Tools TM 9-2320-280-24P
automotive (Appendix B, Item 1) Personnel Required
One mechanic
One assistant
NOTE
. For removal of rear cargo tiedown, one assistant will be needed.
Early production vehicles will have a capscrew in place of a hex
●
head screw.
1. Remove hex head screw (1) and front cargo tiedown (2) from cargo floor (3).
2. Remove locknut (7), washer (6), hex head screw (4), and rear cargo tiedown (5) from cargo floor (3).
NOTE
For installation of rear cargo tiedown, one assistant will be needed.
1. Install front cargo tiedown (2) on cargo floor (3) with hex head screw (1). Tighten capscrew ( 1) to
65 lb-ft (88 N-m).
2. Install rear cargo tiedown (5) on cargo floor (3) with hex head screw (4), washer (6), and locknut (7).
Tighten locknut (7) to 65 lb-ft (88 N.rn).
10-92
TM 9-2320-280-20-3
1 0 - 5 7 . FIRE EXTINGUISHER BRACKET REPLACEMENT
This task covers:

INITIAL SETUP:
Materials/Parts
NOTE
M1097A1, M1097A2, and M1123 models fire extinguisher bracket
and retainer plate is mounted on the floor, left side of driver’s seat,
with capscrews securing retainer plate instead of wing head studs.
a. Removal
1. Turn two wing head studs (4) and remove driver’s seat base retainer plate (7) from driver's seat
base (3).
2. Remove four locknuts (1), washers (2), capscrews (6), washers (2), and fire extinguisher bracket (5)
from driver's seat base retainer plate (7). Discard locknuts (1).
b. Installation
1. Install fire extinguisher bracket (5) on driver's seat base retainer plate (7) with four washers (2),
capscrews (6), washers (2), and locknuts (1). Tighten locknuts (1) to 6 lb-ft (8 N·m).
2. Install driver's seat base retainer plate (7) on driver's seat base (3) with two wing head studs (4).
M1097A1, M1097A2,
AND M1123
Change 1 10-93
TM 9-2320-280-20-3
10-58. FIRE EXTINGUISHER SUPPORT REPLACEMENT
This task covers:

INITIAL SETUP:
M966, M996, M997, M998, M1025, M1026, TM 9-2320-280-24P
M1035, M1036, M1037, M1038, M1042,
M1043, M1044, M1045, M1046 Equipment Condition
Fire extinguisher bracket removed (para. 10-57).

Remove two nuts (4), washers (3), capscrews (1), washers (6), and fire extinguisher support (2) from
driver’s seat base retainer plate (5).
I b. Installation
I
Install the extinguisher support (2) on driver’s seat base retainer plate (5) with two washers (6),
capscrews (1), washers (3), and nuts (4). Tighten nuts (4) to 21 lb-in. (2 N=m).
FOLLOW-ON TASK: Install fire extinguisher bracket (para. 10-57).
10-94
TM 9-2320-280-20-3
I 10-59. DRIVER’S SEAT RETAINER PLATE ASSEMBLY REPLACEMENT I

This task covers:
lNITIAL SETUP:
M966, M996, M997, M998, M1025, M1026, TM 9-2320-280-24P
M1035, M1036, M1037, M1038, M1042,
M1043, M1044, M1045, M1046 Equipment Condition
Fire extinguisher support removed (para. 10-58).
Tools
Materials/Parts
Rivet (Appendix G, Item 181)
NOTE
Remove rivet (3) and retaining cable (2) from seat base (1) and remove driver’s seat base retainer
plate (4) and retaining cable (2).
Install driver’s seat base retainer plate (4) and retaining cable (2) on driver’s seat base (1) with rivet (3).
FOLLOW-ON TASK: Install fire extinguisher support (para. 10-58).
10-95
TM 9-2320-280-20-3
10-60. TAILGATE CHAIN AND BRACKETS REPLACEMENT

This task covers:
lNITIAL SETUP:
All models except M996, M996A1, M997, TM 9-2320-280-10
M997A1, M997A2 TM 9-2320-280-24P
General mechanic’s tool kit Tailgate lowered (TM 9-2320-280-10).
Materials/Parts
a Removal I
1. Open tailgate chain cap link (6) and disconnect tailgate chain (7) from bracket (9).
2. Unhook tailgate chain (7) from tailgate chain bracket (4) and remove tailgate chain (7).
3. Remove four locknuts (1), washers (2), capscrews (5), washers (2), angle bracket (10), chain
bracket (9), and latch bracket (4) from body (3). Discard locknuts (1).
NOTE
Perform step 4 only if tailgate chain cover is damaged.
4. Remove cover (8) from tailgate chain (7).
b. Installation
NOTE
Perform step 1 only if tailgate chain cover was removed.
1. Install cover (8) on tailgate chain (7).
2. Install angle bracket (10), chain bracket (9), and latch bracket (4) on body (3) with four washers (2),
capscrews (5), washers (2), and locknuts (1). Tighten capscrews (5) to 15 lb-ft (20 N.m).
3. Hook tailgate chain (7) to tailgate chain bracket (4).
4. Connect tailgate chain cap link (6) to bracket (9) by closing chain cap link (6).
10-96
TM 9-2320-280-20-3
10-60. TAlLGATE CHAIN AND BRACKETS REPLACEMENT (Cont’d) I
M1037, M1042 ONLY
FOLLOW-ON TASK: Raise and secure tailgate (TM-9-2320-280-10).
10-97
TM 9-2320-280-20-3
10-61. TAlLGATE REPLACEMENT

This task covers:
lNITIAL SETUP:
M997A1, M997A2, M1037, M1042
Equipment Condition
Tools M1025, M1025A1, M1025A2, M1026, M1026A1,
General mechanic’s tool kit: M1036, M1043, M1043A1, M1043A2, M1044,
automotive (Appendix B, Item 1) M1044A1, M1045, M1045A1, M1045A2, M1046,
and M1046A1 only:
Materials/Parts Camouflage pack stowage straps removed
Six locknuts (Appendix G, Item 106) (para. 10-9).
Personnel Required
One mechanic
One assistant
1. Remove six locknuts (10), washers (9), and capscrews (7) from tailgate (3) and body (2). Discard
locknuts (10).
2. Disconnect two tailgate chains (1) from tailgate (3) and remove tailgate (3) and shims (8).
NOTE
● Perform step 3 if replacing seal(s).
l Seal across bottom of tailgate is used on TOW and armament

carrier vehicles only.
. Vehicles equipped with tailgate upper hinge kit, P/N 12342446
will have a three-piece seal.
3. Remove seals (4) and (6) from tailgate (3).
4. Clean adhesive from tailgate (3).
I b. Installation
I NOTE
. Perform step 1 if replacing seal(s).
Q Seal across bottom of tailgate is used on TOW and armament
carrier vehicles only.
. Vehicles equipped with tailgate upper hinge kit, P/N 12342446,
will have a three-piece seal.
1. Peel paper backing (5) from seals (4) and (6) and install seals (4) and (6) on tailgate (3).
2. Install shims (8) and tailgate (3) on body (2) with six capscrews (7), washers (9), and locknuts (10).
Tighten capscrews (7) to 26 lb-ft (35 N.m).
3. Connect two tailgate chains (1) to tailgate (3).
10-98
TM 9-2320-280-20-3
10-61. TAlLGATE REPLACEMENT (Cont’d)
FOLLOW-ON TASK: M1025, M1025A1, M1025A2, M1026, M1026A1, M1036, M1043, M1043A1, M1043A2,
M1044, M1044A1, M1045, M1045A1, M1045A2, M1046, and M1046A1 only
Install camouflage pack stowage straps (para. 10-9).
10-99
TM 9-2320-280-20-3
10-62. TAlLGATE UPPER HINGE REPLACEMENT

This task covers:
INITIAL SETUP:
AU models except M996, M996A1, M997, One mechanic
M997A1, M997A2, M1037, M1042 One assistant
Equipment Condition
Materials/Parts Tailgate removed (para. 10-61).
a. Removal I NOTE
. Left and right tailgate upper hinge replacement procedures are
basically the same. This procedure covers the left tailgate upper
hinge.
● Seal across bottom of tailgate is used on TOW and armament
carrier vehicles only. For access to capscrews, a small portion of
the seal has to be removed.
. The upper hinge is installed with rivets during manufacturing.
A kit has been developed to repair the upper hinge. Use kit P/N
57K0107 for installation.
1. Remove seal (10) from tailgate (6) behind upper hinge (7).
NOTE
● Perform step 2 for TOW and armament carrier vehicles only.
Perform step 3 for all other vehicles.
● Note direction of capscrews for installation.
2. Remove two locknuts (8), washers (4), spacers (5), capscrews (3), and washers (4) from upper
hinge (7) and tailgate (6). Discard locknuts (8).
3. Remove three locknuts (8), washers (4), spacers (5), capscrews (3), and washers (4) from upper
hinge (7) and tailgate (6). Discard locknuts (8).
4. Remove three locknuts (9), washers (1), capscrews (2), washers (1), and upper hinge (7) from tail-
gate (6). Discard locknuts (9).
5. Remove pin (12) and lower hinge (11) from upper hinge (7).
b. Installation
1. Install lower hinge (11) on upper hinge (7) with pin (12).
2. Install upper hinge (7) on tailgate (6) with three washers (1), capscrews (2), washers (1), and
locknuts (9). Tighten locknuts (9) to 8 lb-ft (11 N.m).
NOTE
Perform step 3 for TOW and armament carrier vehicles only.
Perform step 4 for all other vehicles.
3. Secure upper hinge (7) to tailgate (6) with two washers (4), capscrews (3), spacers (5), washers (4),
and locknuts (8). Tighten locknuts (8) to 8 lb-ft (11 N.m).
10-100
TM 9-2320-280-20-3
10-62. TAlLGATE UPPER HINGE REPLACEMENT (Cont’d) I

4. Secure upper hinge (7) to tailgate (6) with three washers (4), capscrews (3), spacers (5), washers (4),
and locknuts (8). Tighten locknuts (8) to 8 lb-ft (11 Nom).
5. Install seal (10) on tailgate (6) behind upper hinge (7).
FOLLOW-ON TASK: Install tailgate (para. 10-61).
10-101
TM 9-2320-280-20-3
10-63. MUD FLAP INSTALLATION

I
This task covers:
Installation
INITIAL SETUP
Materials/Parts
Two mud flaps (Appendix D, Fig. D-88)
Eight locknuts (Appendix G, Item 103).
Installation
NOTE
Mud flap installation will prevent stones thrown by tires from
hitting other vehicles. Installation is at commander’s discretion.
Refer to appendix D, Fig. D-88.
1. Remove two capscrews (4) and washers (3) from shield (5) and body (1).
2. Install mud flap assembly (2) on shield (5) and body (1) with two washers (3) and capscrews (4).
3. Repeat steps 1 and 2 for opposite side.
10-102
TM 9-2320-280-20-3
10-64. BODY HINGE MOUNT REPLACEMENT

This task covers:
INITIAL SETUP:
General mechanic’s tool kit: M998, M998A1, M1035, M1035A1, M1035A2,
automotive (Appendix B, Item 1) M1037, M1038, M1038A1, M1042 only:
● Soft top door removed (TM 9-2320-280-10).
Manual References M966, M966A1, M996, M996A1, M1025, M1025A1,

TM 9-2320-280-10 M1025A2, M1026, M1026A1, M1043, M1043A1,
TM 9-2320-280-24P M1043A2, M1044, M1044A1, M1045, M1045A1,
M1045A2, M1046 and M1046A1 only
● Ballistic crew door removed (para. 11-2).
NOTE
Perform step 1 for upper front body hinge removal.

1. Remove two nuts (1), washers (2), twelve-point screws (5), washers (4), and upper front body hinge
mount (3) from body (6).
NOTE
Perform step 2 for lower front body hinge removal.
2. Remove two twelve-point screws (9), washers (8), and lower front body hinge mount (7) from body (6).
b. Installation
NOTE
Perform step 1 for lower and rear body hinge mount installation.
1. Install lower body hinge mount (7) on body (6) with two washers (8) and twelve-point screw (9).
Tighten twelve-point screws (9) to 8 lb-ft (11 Nom).
NOTE
Perform step 2 for upper front body hinge installation.
2. Install upper body hinge mount (3) on body (6) with two washers (4), twelve-point screws (5),
washers (2), and nuts (1). Tighten twelve-point screws (5) to 8 lb-ft (11 N-m).
FOLLOW-ON TASKS: M998, M998A1, M1035, M1035A1, M1035A2, M1037, M1038, M1038A1, M1042 only
● Install soft top door (TM 9-2320-280-10).
M966, M966A1, M996, M996A1, M1025, M1025A1, M1025A2, M1026, M1026A1,
M1043, M1043A1, M1043A2, M1044, M1044A1, M1045, M1045A1, M1045A2,
M1046 and M1046A1 only:
● Install ballistic crew door (para. 11-2).
● Adjust soft top door (para. 10-102).
10-103
TM 9-2320-280-20-3
10-65. AIRLIFT BRACKET TO HOOD SEAL REPLACEMENT

This task covers:
INITIAL SETUP:
General mechanic’s tool kit Hood raised and secured (TM 9-2320-280-10).
Manual References
TM 9-2320-280-10
TM 9-2320-280-24P
Remove protector (1) and seal (2) from airlift bracket (3).
Install seal (2) and protector (1) on airlift bracket (3).
10-104
TM 9-2320-280-20-3
10-66. BODY REPAIR

This task covers:
a. General c. Rivet Replacement
b. Inspection
lNITIAL SETUP:
Tools Materials/Parts
General mechanic’s tool kit Sealing compound (Appendix C, Item 40)
Manual References
Special Tools TM 9-2320-280-24P
‘Tool kit, riveter (Appendix B, Item 139)
1. The M998 series body is constructed from aluminum alloys that have been heat treated to obtain
high strength. Welding cannot be used to make body repairs. Heat generated in welding will reverse
the heat treatment process and cause a great reduction in strength of material.
2. Solid 3/16 inch diameter aluminum rivets are the primary method of joining body components.
Rivets are inserted into a hole through two pieces of metal and a second head is formed by manual
or pneumatic impacting. or by squeezing the rivet. A bucking bar is used to backup the rivet to form
rivet head. When making repairs, use blind rivets of the same size or oversize diameter with the
appropriate grip length.
3. Blind structural aluminum rivets of 3/16 inch diameter are used in applications where there is
access from only one side of the part. Blind rivets are installed using a tool that pulls on the rivet
stem causing a bulbed head to form on the back side of the part. Fastening is complete when stem
breaks off. High strength is obtained in blind structural rivets by mechanically locking the
remaining stem inside rivet body. Blind pop rivets are used in locations where non-structural
attachments such as latches, striker plates, etc., are attached to the body.
4. Steel pull-type lockbolt fasteners in 3/16 and 1/4-inch diameter are used where tension or high shear
loads exist. Lockbolts are two-piece unthreaded fasteners. One part is a high-strength, steel-headed
bolt-like part with aberrations on its shank. The mating part is a collar which is swaged over the
serrations causing the fastener to be locked in place.
5. Rivnut/plusnut fasteners are tubular rivets with internal threads. Rivnut/plusnut fasteners are
installed using a tool that engages the threads of the fastener and extends a pull, causing the shank
to expand tightly against the material being fastened. This process is called “upsetting” a
rivnut/plusnut.
6. Rivet and Lockbolt replacement.
To facilitate repairs to body, it is acceptable to replace lockbolts and rivets with 1/4 inch AN4 series
bolts. Do not replace lockbolts with rivets. Standard threaded fasteners should not be used, as these
will quickly wear the aluminum structure. Bolt lengths should be chosen so that the cylindrical
portion of bolt is bearing on all members being joined. Bolts are designated as AN4-XX or AN4C-XX
where XX defines grip length. Tighten all bolts to 70-75 lb-in. (8-9 N.m).
7. Fatigue strength of riveted joints and seams is increased by one part epoxy adhesive. This adhesive
requires special material storage and metal preparation along with a low temperature heat cycle for
curing. Because of its impracticality in field repairs, epoxy adhesive will not be used. Where
possible, extra rivets and thicker metal gages should be used instead of adhesives. When making
repairs, note epoxy exists and that parts may be difficult to separate, even after rivets are removed.
10-105
TM 9-2320-280-20-3
10-66. BODY REPAIR (Cont’d)
1. The damaged area should be thoroughly cleaned and inspected to determine cause and extent of
damage. Body parts should be inspected for holes, cracks, dents, distortion, or breaks. Fasteners
should be inspected for breaks, stretching, looseness, cocked heads, or hole elongation. Seams,
flanges, and joints should be inspected for straightness or local deformation as an indication that
fasteners may have been stretched or holes elongated. It is possible for this to happen and fasteners
still appear to be tight in their holes. In addition, make thorough inspection of adjacent areas to
determine if high loads have been transmitted from the damaged area to other areas. This can
result in secondary damage in the form of distorted panels or seams, loosened or sheared fasteners,
elongated fastener holes, and cracks.
2. Signs of rivet failure include tipped heads, looseness, and sometimes chipped or cracked paint. If
heads are tipped in the same direction and rivets are loose in consecutive groups, the joint has
undergone excessive load. Rivet heads which are tipped in different directions and are not in groups
may be improperly installed. With chipped or cracked paint, it may be necessary to remove paint to
check true condition of rivets. Rivets subjected to critical loads but showing no distortion, should be
inspected if failure is suspected. The head should be drilled off, and the shank should be carefully
punched out. Failure is indicated by notched rivet shank and misaligned holes. Flush rivets showing
head slippage within the dimple or countersink indicate either sheet bearing or rivet shear failure
and must be removed for inspection and replacement. If failure of rivets cannot be detected by visual
inspection, the joint can be checked by drilling and punching out several rivets. If rivet shanks are
notched, rivets should be replaced with next larger size rivets. If rivet holes show elongation due to
local failure in tearing of the sheet, next larger size rivet must be used in replacement. Any
deformation of the sheet around the rivet, tear outs, or cracks between rivets usually indicates
partially failed or damaged rivets. Complete repair of the joint will require replacement by next
larger size rivets. Use the next 1/32 inch larger diameter rivet to obtain a tight joint when original
hole has been enlarged. If original size rivet is installed, the rivet would not be able to carry its
share of the shear load, and the joint would not meet its strength requirement.
c. Rivet Replacement
NOTE
When removing rivets, care should be taken to not enlarge rivet
hole as this would require use of an oversize or larger rivet for
replacement.
1. Solid Rivet Removal.
(a) File a flat surface on the manufactured head if accessible, It is always preferable to work on
manufactured head rather than the one that is bucked over, since the former will always be
more symmetrical about the shank.
(b) Indent center of the filed surface with a center punch.
(c) Drill through rivet head. Be sure to use a drill slightly smaller than diameter of rivet shank to
avoid making rivet hole oversized.
(d) Shear weakened rivet head off with a sharp chisel. For this operation, support back side of rivet
and cut rivet head along direction of rivet line or panel edge. This will prevent distortion of the
panel.
(e) Firmly support the panel from the opposite side and drive out shank with a pin punch. If rivet is
unduly tight because of swelling between sheets, drill rivet shank out with an undersize drill.
2. Blind Rivet Removal.
(a) File a small flat on rivet head.
(b) Center punch the flat. Support rivet backside, if possible.
(c) Using a small drill about the size of rivet pin, drill off tapered end of pin which forms the lock.
10-106
TM 9-2320-280-20-3
I 10-66. BODY REPAIR (Cont’d) I

(d) Shear lock using a pin punch to drive out pin.
(e) Pry out remainder of locking collar.
(f) Using a drill slightly smaller than rivet shank, drill almost through rivet head.
(g) Pry off rivet head with a pin punch.
(h) Tap out rivet shank with a pin punch.
3. Rivnut/Plusnut Removal.
(a) Drill through rivnut head.
(b) Punch out shank.
4. Rivet Hole Drilling.
(a) Center punch all new rivet locations. Center punch mark must be large enough to prevent drill
from slipping out of position, yet it must not dent the surface of the material. To prevent denting,
place a bucking bar behind material during punching.
(b) Make sure drill is the correct size (tables 10-1 and 10-2) and point is properly ground. A no. 10
drill is used to install standard 3/16-inch blind rivets.
Table 10-1. Drill Sues for Solid Shank Rivets
Table 10-2. Drill Sizes for Blind Rivets
(c) Place drill in center mark for new rivet locations, or align drill with old hole when replacing old
rivets with oversize rivets. When using a power drill, give the bit a few turns with fingers before
starting motor. This will help assure that drill does not jump out of position when motor is
started.
10-107
TM 9-2320-280-20-3
10-66. BODY REPAIR (Cont’d) I

NOTE
● While drilling, hold drill at 90 degree angle to material surface.
Avoid letting drill wobble, marking oblong holes.
● Avoid excessive pressure. Let drill bit do the cutting.
● Do not push drill through material.
(d) Remove all burrs with a metal countersink or file.

(e) Clean away all drill chips. Care must be taken to assure that no chips are trapped between
sheets of metal.
(f) Apply sealing compound to hole and surrounding area.
5. Hole Countersinking.
NOTE
Some rivet installations in the body require that rivet head be
flush with the material surface. In these instances, countersunk or
flush head rivets are used.
(a) When using countersunk rivets, rivet holes must be countersunk with a tool having a 100” taper
so rivet head will fit flush with surface.
(b) When using a hand-operated countersink, the hole must be tried with a rivet so the recess will
not be too deep or too shallow. It is best to use a countersink with a stop on it so depth of
countersink can be controlled. Typical countersinking dimensions for blind rivets are shown in
table 10-3. The minimum sheet thickness that can be machined for 100° countersink rivets is
given in table 10-4.
(c) Do not remove edge of hole on blind side of joint.
Table 10-3. Countersinking Dimensions for

100° Countersunk Blind Rivets
Table 10-4. Minimum Sheet Gage& 100° Machine Countersink
10-108
TM 9-2320-280-20-3
6. Blind Rivet Driving Practices and Precautions.

(a) Rivets should be inspected for proper installation. The grip length of each rivet is marked on top
of its head to provide positive identification. Use of proper grip length will produce a rivet
installation where locking collar is flush with top surface of rivet head. Tolerance limit on
flushness is 0.020 in. (0.5 mm).
(b) For proper rivet installation, it is imperative that holes be properly prepared, tools be in good
working order, and rivets properly applied. When problems occur, the source of trouble could be
in any of these areas.
7. Blind Rivet Installation.
NOTE
● Prior to installing blind rivets, the hole must be prepared, the
parts aligned and clamped firmly in place. These steps are the
same as for solid riveting operations. Proper drill sizes for
standard and oversized blind rivets are given in table 10-2.
Countersinking dimensions and minimum sheet gage for
countersunk blind rivets are shown in tables 10-3 and 10-4.
. It is very important that the proper length rivet is selected for
each application. Rivet lengths are sized by the range of material
thickness that the rivet will grip. Selecting the proper rivet
length is critical because rivets can tolerate only 1/16 inch
variation in material thickness for each particular rivet length.
Rivet grip lengths are called out as a “dash number” at the end
of the manufacturer’s part number. Grip lengths are determined
as shown in table 10-5.
● For double dimpled sheets, add countersunk head height to
materials thickness.
● Use rivet installation tool kit for all blind rivets.
Table 10-5. Rivet Grip Length Determination
10-109
TM 9-2320-280-20-3
(a) Insert rivet stem into pulling head of rivet gun.

(b) Hold rivet gun in line with axis of rivet as accurately as possible.
(c) Apply a shady firm pressure against rivet head.
(d) Squeeze handles of manual gun. The rivet clamping action will pull sheets together, seat rivet
head, and break stem flush with head of rivet.
8. Rivnut/Plusnut/Insertnut Installation.
(a) Thread rivnut onto mandrel of installation tool.
(b) Insert rivnut into hole for installation.
(c) Apply steady firm pressure against rivnut head.
(d) Squeeze hades of tool to clinch rivnut shank against material.
(e) Remove mandrel from rivnut.
10-110
TM 9-2320-280-20-3
1 0 - 6 7 . “B” PILLAR REPLACEMENT
This task covers:

INITIAL SETUP:
M998, M998A1, M1035, M1035A1, M1035A2, TM 9-2320-280-10
M1037, M1038, M1038A1, M1042 TM 9-2320-280-24P
General mechanic’s tool kit: • Soft top removed, if installed (TM 9-2320-280-10).
automotive (Appendix B, Item 1) • Soft top door strikers removed, if installed
(para. 10-103).
Materials/Parts • Three point seatbelt removed (para. 10-48 or
Twelve locknuts (Appendix G, Item 76) 10-48.1).
a. Removal
Remove twelve locknuts (5), washers (4), capscrews (2), and “B” pillar (1) from body (3). Discard
locknuts (5).
b. Installation
Install “B” pillar (1) on body (3) with twelve capscrews (2), washers (4), and locknuts (5). Tighten
locknuts (5) to 15 lb-ft (20 N•m).
FOLLOW-ON TASKS: • Install soft top, if removed (TM 9-2320-280-10).

• Install soft top door strikers, if removed (para. 10-103).
• Install three point seatbelt (para. 10-48 or 10-48.1).
Change 1 10-111
TM 9-2320-280-20-3
1 0 - 6 8 . M11 DECONTA M I N ATION BRACKETS INSTALLATION
This task covers:

Installation
INITIAL SETUP:
M966, M966A1, M998, M998A1, M1025, General mechanic’s tool kit:
M1025A1, M1025A2, M1026, M1026A1, automotive (Appendix B, Item 1)
M1036, M1037, M1038, M1038A1, M1042,
M1121 Manual References
TM 9-2320-280-10
TM 9-2320-280-24P
NOT E
The following procedure is for initial installation of apparatus (P/N D5-
51-269). This apparatus is not included in TM 9-2320-280-24P.
Installation
NOT E
Perform steps 1 and 2 for models M966, M966A1, and M1036 vehicles only.
1. Using bracket (2) as a template, locate, mark, and drill four 0.281-inch (7.14 mm) diameter holes (1)
in right wheel housing (4).
2. Install bracket (2) on right wheel housing (4) with four washers (3), screws (5), washers (3), and
nuts (6).
NOT E
Perform steps 3 and 4 for models M998, M998A1, M1038, and M1038A1
vehicles only.
3. Using bracket (9) as a template, locate, mark, and drill four 0.281-inch (7.14 mm) diameter
holes (10) in left wheel housing (11).
4. Install bracket (9) on left wheel housing (11) with four washers (7), screws (8), washers (7), and
nuts (12).
10-112 Change 1
TM 9-2320-280-20-3
10-68. M11 DECONTAMINATION BRACKETS INSTALLATION (Cont’d)
NOTE
Perform steps 5 through 10 for models M1025, M1025A1,
M1025A2, M1026, and M1026A1 vehicles only.
5. Using bracket (17) as a template, locate, mark, and drill a 0.281-inch (7.14 mm) diameter hole (22)
through armor panel (13) and left wheel housing (25).
6. Install bracket (17) on armor panel (13) and left wheel housing (25) with washer (21), screw (20),
washer (21), and nut (24). Do not tighten nut (24).
7. Position M11 decontaminating apparatus (19) in bracket (17) with handle (18) toward rear of
vehicle.
8. Place top of M11 decontaminating apparatus (19) and bracket (17) between rear seat (16) and M13
decontamination mount bracket (23) in an upright position. Using bracket (17) as a template, scribe a
reference line (14) on armor panel (13). Remove M11 decontaminating apparatus (19) from bracket (17).
9. Using marked reference line (14) on armor panel (13) and bracket (17) as a template, locate, mark,
and drill two 0.281-inch (7.14mm) diameter holes (15).
10. Install bracket (17) on armor panel (13) with two washers (21), screws (20), washers (21), and
nuts (24). Tighten screw (20) and nut (24) installed in step 6.
10-113
TM 9-2320-280-20-3
10-68. M11 DECONTAMINATION BRACKETS INSTALLATION (Cont’d)

I
NOTE
Perform steps 11 through 14 for model M1037 and M1042 vehicles
only.
11. Remove left rear fixed door (1) (para. 10-14).
12. Using bracket (4) as a template, locate, mark, and drill four 0.281-inch (7.14 mm) diameter holes (5)
in left rear fixed door (1).
13. Install bracket (4) on left rear fixed door (1) with four washers (2), screws (6), washers (2), and
nuts (3).
14. Install left rear fixed door (1) (para. 10-14).
10-114
TM 9-2320-280-20-3
Section II. BODY ACCESSORIES MAINTENANCE
1 0 - 6 9 . BODY ACCESSORIES MAINTENANCE TASK SUMMARY
TASK PAGE
PROCEDURES
PARA. NO.
10-70. Windshield Wiper Blade and Arm Maintenance 10-116
10-71. Windshield Wiper Motor (SF5578716) Replacement 10-118
10-72. Windshield Wiper Switch/Motor (12342501) Replacement 10-120
10-73. Windshield Wiper Linkage Replacement 10-122
10-74. Windshield Wiper Arm Pivot Replacement 10-123
10-75. Windshield Washer Reservoir and Pump 10-124
Assembly Replacement
10-76. Windshield Washer Hoses Replacement 10-126
10-77. Sun Visor Replacement 10-128
10-78. Windshield Washer Nozzle Replacement 10-129
10-79. Mirror Replacement 10-130
10-80. Mirror Arm Assembly Replacement 10-131
10-81. Mirror Mounting Bracket Replacement 10-132
10-82. Rearview Mirror Maintenance 10-133
10-83. Heater Shutoff Valve Replacement 10-137
10-84. Heater Outlet/Inlet Piping Maintenance 10-138
10-85. Heater Fan Switch Replacement 10-140
10-86. Heater Fan Motor Resistor Assembly Replacement 10-142
10-87. Heater Assembly Replacement 10-144
10-88. Defrost Control Replacement 10-146
10-89. Heater Control Replacement 10-148
10-90. Heater Control Cable and Shutoff Valve Adjustment 10-150
10-91. Heater Ducting Replacement 10-152
10-92. Diverter Box Replacement (All except M998A2) 10-154
10-92.1. Diverter Manifold and Housing Replacement 10-154.2
10-93. Defroster Ducting Replacement (All except M1097A2, M1123) 10-156
10-94. Left Defroster Nozzle Replacement 10-160
10-94.1. Heater Nozzle Deflector Replacement 10-163
10-95. Right Defroster Nozzle Replacement 10-164
10-96. Heater Boot Replacement 10-164.1
10-96.1. Defroster Ducting Replacement (M1097A2, M1123) 10-164.2
10-96.2. Heater Hose Replacement 10-164.4
10-96.3. Diverter Box Cover Replacement 10-164.5
10-96.4. Diverter Ducting Replacement 10-164.6
10-97. Air Duct Assembly Replacement 10-165
10-97.1. Diverter Box Replacement (M998A2) 10-166
10-98. “A” Pillar Former Assembly Replacement 10-167
10-99. “C” Pillar Replacement 10-168
Change 1 10-114.1/(10-114.2 blank)

TM 9-2320-280-20-3
1 0 - 6 9 . BODY ACCESSORIES MAINTENANCE TASK SUMMARY (Cont’d)
TASK PAGE
PROCEDURES
PARA. NO.
10-100. Rear Bow Pivot Bracket Replacement 10-169
10-101. Soft Top Door Hinge Replacement 10-170
10-102. Soft Top Door Adjustment 10-172
10-102.1. Soft Top Door Handle Repair 10-172.2
10-103. Soft Top Door Striker Replacement 10-174
10-104. Soft Top Repair 10-175
10-105. “C” Pillar Reinforcement Brackets Installation 10-177
Change 1 10-115
TM 9-2320-280-20-3
10-70. WINDSHIELD WIPER BLADE AND ARM MAINTENANCE

This task covers:
a. Removal c Installation
b. Repair (Optional)
lNITIAL SETUP:
Materials/Part
Spring (Appendix G, Item 237)
NOTE
Ensure windshield wiper motor switch is in off position. Note
position of wiper arm for installation.
a. Removal
NOTE
Perform only if blade assembly is to be replaced.
Remove screw (1), nut (10), and blade assembly (8) from wiper arm (2).
I b. Repair (Optional) I
NOTE
If spring inside wiper arm looses its tension, it can be replaced
with spring as an alternate to replacing the wiper arm.
1. Lift wiper arm (2) away from windshield (9).
2. Lift up latch (3) at base of wiper arm (2) and remove wiper arm (2) from splined shaft (4).
3. Remove spring (7) from wiper arm (2). Discard spring (7).
4. Install spring (7) in second hole (6) of wiper arm tabs (5).
5. Ensure wiper arm latch (3) is unlocked.
NOTE
With motor switched off (parked position), mount wiper arm
approximately 60° to vertical centerline, so that a sweep of
approximately 120° will be achieved in operation.
6. Install wiper arm (2) on splined shaft (4).
c. Installation
NOTE
Perform only if blade assembly was removed.
Install blade assembly (8) on wiper arm (2) with screw (1) and nut (10).
10-116
TM 9-2320-280-20-3
10-70. WINDSHIELD WIPER BLADE AND ARM MAINTENANCE (Cont’d)
FOLLOW-ON TASK: Check windshield wiper for proper operation (TM 9-2320-280-10).
10-117
TM 9-2320-280-20-3
10-71. WINDSHIELD WIPER MOTOR (SF5578716) REPLACEMENT

This task covers:
INITIAL SETUP:
Adhesive-sealant (Appendix C, Item 10) Battery ground cable disconnected (para. 4-73).
Gasket (Appendix G, Item 47)
1. Disconne Ct connector (20) from wiper motor (15).

2. Remove screw (16) and washer (17) from wiper motor bracket (18) and windshield frame (1).
3. Remove screw (12), lockwasher (11), and ground lead 57G (10) from wiper motor (15). Discard
lockwasher (11).
4. Remove three capscrews (9) and washers (8) from antenna cable clamp (7) (M996, M996A1, M997,
M997A1, and M997A2 only), wiper motor mounting plate (4), and windshield frame (1).
5. Pull wiper motor mounting plate (4) and wiper motor (15) away from windshield frame (1) for access
to capscrew (2).
6. Remove screw (14) and lockwasher (13) from wiper motor (15) and motor mounting plate (4), and
separate wiper motor (15) and gasket (19) from motor mounting plate (4). Discard lockwasher (13)
and gasket (19).
7. Remove capscrew (2) from motor drive lever assembly (3) and wiper motor (15), and remove wiper
motor (15) and wiper motor mounting plate (4) from windshield frame (1).
8. Remove right access cover (6) from windshield frame (1).
b. Installation
NOTE
● Coat wiper motor and both sides of mounting plate with adhesive-
sealant. Allow to dry approximately 2 hours.
● To ease future wiper/motor removal and installation, the twelve
point screws used in steps 1 and 3 may be discarded and replaced
with hex head screws (NSN 5305-00-071-2505).
1. Install wiper motor (15) and gasket (19) on wiper motor mounting plate (4) with lockwasher (13) and
screw (14).
2. Position wiper motor mounting plate (4), gasket (19), and wiper motor (15) in windshield frame (1)
and install motor drive lever assembly (3) on wiper motor (15) with capscrew (2).
3. Install ground lead 57G (10) and wiper motor (15) on wiper motor mounting plate (4) with
lockwasher (11) and screw (12).
4. Install wiper motor mounting plate (4) and antenna cable clamp (7) (M996, M996A1, M997,
M997A1, and M997A2 only) on windshield frame (1) with three washers (8) and capscrews (9).
Finger tighten only.
5. Connect connector (20) to wiper motor (15).
6. Connect battery ground cable (para. 4-73).
7. Place wiper motor switch to “ON” position (TM 9-2320-280-10). Pivot crank (5) must travel an equal
distance to each side of vertical centerline. To adjust swing of pivot crank (5), slide wiper motor
mounting plate (4) to left or right for correct swing.
10-118
TM 9-2320-280-20-3
10-71. WINDSHIELD WIPER MOTOR (SF5578716) REPLACEMENT (Cont’d)
8. Install wiper motor bracket (18) on windshield frame (1) with washer (17) and screw (16).
9. Install right access cover (6) on windshield frame (1).
FOLLOW-ON TASKS: ● Connect battery ground cable (para 4-73).

● Check wiper motor for proper operation (TM 9-2320-280-10).
10-119
TM 9-2320-280-20-3
10-72. WINDSHIELD WIPER SWITCH/MOTOR (12342501) REPLACEMENT

This task covers:
INITIAL SETUP:
Two lockwashers (Appendix G, Item 124) Battery ground cable disconnected (para. 4-73).
a. Removal
NOTE
Perform steps 1 through 4 for removal of wiper motor switch.
Proceed to step 5 for removal of wiper motor assembly.
1. Disconnect lead (12) from wiper switch (11).
2. Depress retaining clip on back of knob (15) and remove knob (15) from wiper switch (11).
3. Remove nut (14) and lockwasher (13) from wiper switch (11) and wiper motor mounting plate (10).
Discard lockwasher (13).
4. Disconnect switch connector (9) from wiper motor (5) and remove wiper switch (11).
5. Remove screw (16) and lockwashers (17) and (19) from ground lead 57G (18) and wiper motor
mounting plate (10). Discard lockwashers (17) and (19).
6. Remove three capscrews (8) and washers (7) from antenna cable clamp (6) (M996 and M997 only),
wiper motor (5), and windshield frame (2).
7. Pull wiper motor (5) away from windshield frame (2) for access to clip (3).
8. Remove clip (3) and disconnect connecting links (1) and (4) from wiper motor (5) and remove wiper
motor (5) from windshield frame (2).
NOTE
Perform steps 1 through 4 for installation of wiper motor switch.
Proceed to step 5 for installation of wiper motor assembly.
1. Install wiper switch (11) on wiper motor mounting plate (10) with lockwasher (13) and nut (14).
2. Depress retaining clip on back of knob (15) and install knob (15) on wiper switch (11).
3. Connect switch connector (9) to wiper motor (5).
4. Connect lead (12) to wiper switch (11).
5. Position wiper motor (5) in windshield frame (2) install connecting links (4) and (1) on wiper
motor (5) with clip (3).
6. Install wiper motor (5) and antenna cable clamp (6) (M996 and M997 only) on windshield frame (2)
with three washers (7) and capscrews (8).
7. Install ground lead 57G (18) on wiper motor mounting plate (10) with lockwashers (19) and (17) and
screw (16).
10-120
TM 9-2320-280-20-3
10-72. WINDSHIELD WIPER SWITCH/MOTOR (12342501) REPLACEMENT (Cont’d)
FOLLOW-ON TASKS: ● Connect battery ground cable (para 4-73),

● Check wiper motor for proper operation (TM 9-2320-280-10).
10-121
TM 9-2320-280-20-3
10-73. WINDSHIELD WIPER LINKAGE REPLACEMENT

This task covers:
lNITIAL SETUP:
General mechanic’s tool kit: ● Windshield wiper switch/motor (12342501)
automotive (Appendix B, Item 1) removed (para. 10-72).
● Windshield wiper motor (SF5578716) removed
Manual References
(para. 10-71).
TM 9-2320-280-24P
1. Remove two access covers (7) nom windshield frame (1).

2. Pull connector arm retainer (3) from ball stud (5) and remove motor drive lever (6) from connector
arms (4).
3. Disconnect connector arms (4) from wiper arm pivots (2) and remove connector arms (4) through
center access in windshield frame (1).
CAUTlON
Install the left (driver’s) side connector arm first or damage to
equipment will result.
1. Install connector arms (4) through center access on windshield frame (1) and connect connector
arms (4) to wiper arm pivots (2).
2. Connect connector arms (4) together with motor drive lever (6) and connector arm retainer (3) on
ball stud (5).
3. Install access covers (7) on windshield frame (1). /
FOLLOW-ON TASK: ● Install windshield wiper switch/motor (12342501) (para. 10-72).

● Install windshield wiper motor (SF5578716) (para. 10-71).
10-122
TM 9-2320-280-20-3
10-74. WINDSHIELD WIPER ARM PIVOT REPLACEMENT

This task covers:
a. Repair (Optional) c Installation
b. Removal
INITIAL SETUP
General mechanic’s tool kit ● Windshield wiper linkage removed (para. 10-73).
automotive (Appendix B, Item 1) ● Windshield wiper blade and arm removed
(para. 10-70).
Manual References
TM 9-2320-280-24P
a. Repair (Optional)
NOTE
● Steps 1 through 3 is an alternative repair for the windshield
wiper arm pivot. The repair can be done at commander’s

discretion.
● For easy handling, use of an old wiper arm as a hole guide is
recommended. This will also protect the splined surface of the

pivot.
● Use roll pin (5315-01-027-4759) for repair.
1. Center punch the side of the wiper arm (1). Position the wiper arm (1) so it is horizontal for drilling
2. Drill a 3/32 in. hole halfway through the center shaft (2). remove the old wiper arm (1), and
continue drilling all the way through the shaft (2) and cap.
3. Using a small hammer or punch drive a roll pin (3) into the hole until it is flush with the surface.
Replace the original wiper arm.
Remove nut (4), washer (5), seal (6), and pivot (8) from windshield frame (7).
c Installation
Install pivot (8) on windshield frame (7) with seal (6), washer (5), and nut (4).
FOLLOW-ON TASKS: . Install windshield wiper blade and arm (para. 10-73).
. Install windshield wiper linkage (para. 10-70).
10-123
TM 9-2320-280-20-3
1 0 - 7 5 . WINDSHIELD WASHER RESERVOIR AND PUMP ASSEMBLY REPLACEMENT
This task covers:

INITIAL SETUP:
Four lockwashers (Appendix G, Item 110) •Battery ground cable disconnected (para. 4-73).
Seal (Appendix G, Item 217) •Hood raised and secured (TM 9-2320-280-10).
a. Removal
1. Disconnect harness leads 71C (6) and 57D (7) from pump leads (5) under dash panel and remove
grommet (3) from cowl (10).
2. Loosen clamp (2) and disconnect windshield washer hose (1) from reservoir and pump assembly (4).
NOT E
Perform step 3 for windshield washer reservoir with non-
removable pump assembly only. Perform steps 4 through 6 for
windshield washer reservoir with removable pump assembly only.
3. Remove two nuts (12), lockwashers (11), capscrews (8), washers (9), and reservoir and pump
assembly (4) from cowl (10). Discard lockwashers (11).
4. Remove three nuts (12), lockwashers (11), capscrews (8), washers (9), and reservoir (18) and pump
assembly (4) from cowl (10). Discard lockwashers (11).
5. Remove nut (16), lockwasher (15), washer (14), capscrew (13), washer (14), and pump assembly (4)
from reservoir (18). Discard lockwasher (15).
6. Remove seal (17) from reservoir (18). Discard seal (17).
b. Installation
NOT E
Perform steps 1 through 3 for windshield washer reservoir with
removable pump assembly only. Perform step 4 for windshield
washer reservoir with non-removable pump assembly only.
1. Install seal (17) on reservoir (18).
2. Install pump assembly (4) on windshield washer reservoir (18) with washer (14), capscrew (13),
washer (14), lockwasher (15), and nut (16). Tighten nut (16) to 6-10 lb-ft (8-14 N•m).
3. Install reservoir (18) and pump assembly (4) on cowl (10) with three washers (9), capscrews (8),
lockwashers (11), and nuts (12). Tighten nuts (12) to 8 lb-ft (11 N•m).
4. Install reservoir and pump assembly (4) on cowl (10) with two washers (9), capscrews (8),
lockwashers (11), and nuts (12). Tighten nuts (12) to 8 lb-ft (11 N•m).
5. Connect windshield washer hose (1) to reservoir and pump assembly (4) and tighten clamp (2).
6. Connect harness leads 71C (6) and 57D (7) to pump leads (5) and install grommet (3) in cowl (10).
10-124 Change 1
TM 9-2320-280-20-3
10-75. WINDSHIELD WASHER RESERVOIR AND PUMP ASSEMBLY REPLACEMENT (Cont’d)
OLD CONFIGURATION
NEW CONFIGURATION
FOLLOW-ON TASKS: c Fill reservoir (TM 9-2320-280-10).

● Lower and secure hood (TM 9-2320-280-10).
10-125
TM 9-2320-280-20-3
1 0 - 7 6 . WINDSHIELD WASHER HOSES REPLACEMENT
This task covers:

INITIAL SETUP:
Manual References
TM 9-2320-280-10
TM 9-2320-280-24P
a. Removal
1. Remove nut (18), washer (4), capscrew (5), and washer (4) from clamp (3), and remove washer
hose (1) from body hood rail (13).
2. Remove two nuts (11), washers (10), capscrews (16), and washers (10) from clamps (9), and remove
washer hose (12) from top of body hood rail (13).
3. Loosen clamp (14) and disconnect washer hose (12) from pump (15) and tee (6), and remove through
clamp (17).
4. Disconnect washer hose (7) from tee (6) and nozzle (8) and remove through clamp (17).
5. Disconnect washer hose (1) from tee (6) and nozzle (2) and remove through clamp (17).
b. Installation
1. Install washer hose (1) through clamp (17) and connect to nozzle (2) and tee (6).
2. Install washer hose (7) through clamp (17) and connect to nozzle (8) and tee (6).
3. Install washer hose (12) through clamp (17) and connect to tee (6) and pump (15) and tighten
clamp (14).
NOTE
When mounting the clamps, ensure they are positioned below the
hood rest, so when the hood is closed it does not interfere with the
clamps or hose.
4. Install washer hose (1) on body hood rail (13) and secure with clamp (3), washer (4), capscrew (5),
washer (4), and nut (18).
5. Install washer hose (12) under body hood rail (13) and secure with two clamps (9), washers (10),
10-126 Change 1
TM 9-2320-280-20-3
10-76. WINDSHIELD WASHER HOSES REPLACEMENT (Cont’d)
10-127
TM 9-2320-280-20-3
1 0 - 7 7 . SUN VISOR REPLACEMENT
This task covers:

INITIAL SETUP:
M997A2, M1025A2, M1035A2, Four lockwashers (Appendix G, Item 109)
M1043A2, M1045A2, M1097A2, M1123
Manual References
Tools TM 9-2320-280-24P
NOT E
The procedure for left and right sun visors is basically the same.
This procedure covers the left sun visor.
a. Removal
1. Remove four capscrews (4), lockwashers (3), and sun visor (1) from windshield frame (2). Discard
lockwashers (3).
2. Inspect four nut inserts (5) for damage. Replace if damaged.
b. Installation
Install sun visor (1) on windshield frame (2) with four lockwashers (3) and capscrews (4).
10-128 Change 1
TM 9-2320-280-20-3
I 10-78. WINDSHIELD WASHER NOZZLE REPLACEMENT

This task covers:
lNITIAL SETUP:
Manual References
TM 9-2320-280-10
TM 9-2320-280-24P
a. Removal
1. Disconnect hose (2) from nozzle (3).
2. Remove screw (1) and nozzle (3) from body (4).
1. Install nozzle (3) on body (4) with screw (1).

2. Connect hose (2) to nozzle (3).
10-129
TM 9-2320-280-20-3
10-79. MIRROR REPLACEMENT

This task covers:
lNITIAL SETUP:
Materials/Parts
Remove locknut (4), washer (3), and mirror (1) from arm assembly (2). Discard locknut (4).
Install mirror (1) on arm assembly (2) with washer (3) and locknut (4). Tighten locknut (4) to 6 lb-ft
(8 N.m).
10-130
TM 9-2320-280-20-3
10-80. MIRROR ARM ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
Equipment Condition
Materials/Parts Mirror removed (para. 10-79).
Nylon washer (Appendix G, Item 152)
1. Remove special nut(1), lockwasher (2), and washer (3) from pivot bracket (4) and mounting
2. Remove mirror arm (7), pivot bracket (4), and nylon washer (6) from mounting bracket (5). Discard
nylon washer (4).
3. Remove nut (10), lockwasher (11), capscrew (8), two spacers (9), and mirror arm (7) from pivot
1. Install two spacers (9) and mirror arm (7) on pivot bracket (4) with capscrew (8), lockwasher (11),
and nut (10). Tighten nut (10) to 15 lb-ft (20 N-m).
2. Install nylon washer (6), pivot bracket (4), and mirror arm (7) on mounting bracket (5) with
washer (3), lockwasher (2), and special nut (1).
FOLLOW-ON TASK: Install mirror (para. 10-79).
10-131
TM 9-2320-280-20-3
10-81. MIRROR MOUNTING BRACKET REPLACEMENT I

This task covers:
INITIAL SETUP:
Equipment Condition
Materials/Parts Mirror arm assembly removed (para 10-80).
Remove four locknuts (5), capscrews (1), washers (2), and mounting bracket (3) from body (4) Discard
locknuts (5).
b. Installation
Install mounting bracket (3) on body (4) with four washers (2), capscrews (1), and locknuts (5). Tighten
FOLLOW-ON TASK: Install mirror arm assembly (para. 10-80).
10-132
TM 9-2320-280-20-3
10-82. REARVIEW MIRROR MAINTENANCE
This task covers:

a. Removal d. Assembly
b. Inspection e. Installation
c. Disassembly
INITIAL SETUP:
Materials/Parts
Five locknuts (Appendix G, Item 106)
Four lockwashers (Appendix G, Item 109)
NOTE
Left and right rearview mirror removal procedures are basically
the same. This procedure covers the left rearview mirror.
a. Removal
Remove two capscrews (3), lockwaahers (4), washers (5), upper mounting bracket (1), lower mounting
bracket (6), and mirror assembly (2) from windshield frame (7). Discard lockwashers (4).
b. Inspection
NOTE
For inspection and removal of blind rivet or insertnut, refer to para. 10-66.
Inspect blind rivet or insertnut (8) for damage. Replace with insertnut if damaged.
10-133
TM 9-2320-280-20-3
10-82. REARVIEW MIRROR MAINTENANCE (Cont’d)
c. Disassembly I
1. Remove two capscrews (10), lockwashers (9), washers (8), spacers (6), and mirror head (5) from
mirror brackets (7). Discard lockwashers (9).
2. Remove locknut (21), washer (22), nylon washers (23) and (2), capscrew (4) and upper mounting
bracket (1) from mirror arm assembly (3). Discard locknut (21).
3. Remove locknut (20), washer (19), and lower mounting bracket (18) from mirror lock (17). Discard
locknut (20).
4. Remove locknut (15), washer (16), and mirror lock (17) from arm assembly (3). Discard locknut (15).
NOTE
To remove clamps, slide clamps off mirror arm assembly.
5. Remove two locknuts (11), washers (12), capscrews (14), two clamps (13), and brackets (7) from mirror
arm assembly (3). Discard locknuts (11).
NOTE
● To install clamps, slide clamps on mirror arm assembly,
Ensure clamps are positioned on mirror arm assembly to align

●
with center of mirror head.

1. Install two clamps (13) and mirror brackets (7) on mirror arm assembly (3). Install mirror
brackets (7) between clamps (13) with two capscrews (14), washers (12), and locknuts (11).
2. Install mirror lock (17) on mirror arm assembly (3) with washer (16) and locknut (15).
3. Install lower mounting bracket (18) on mirror lock (17) with washer (19) and locknut (20).
4. Install upper mounting bracket (1) on mirror arm assembly (3) with capscrew (4), nylon washers (2)
and (23), washer (22), and locknut (21).
NOTE
Spacers must be positioned between mirror head and mirror
brackets for proper installation,
5. Install mirror head (5) and two spacers (6) on mirror brackets (7) with washers (8), lockwashers (9),
and capscrews (10).
10-134
TM 9-2320-280-20-3
10-82. REARVIEW MIRROR MAINTENANCE (Cont’d) I
10-135
TM 9-2320-280-20-3
10-82. REARVIEW MIRROR MAINTENANCE (Cont’d)

I
Install mirror assembly (5) on windshield frame (1) with two washers (2), lockwashers (3), and
capscrews (4).
FOLLOW-ON TASK: Adjust rearview mirror (TM 9-2320-280-10).
10-136
TM 9-2320-280-20-3
10-83. HEATER SHUTOFF VALVE REPLACEMENT

This task covers:
a. Removal b Installation
INITIAL SETUP:
General mechanic’s tool kit Cooling system drained as required (para. 3-60).
Manual References
TM 9-2320-280-10
TM 9-2320-280-24P
1. Remove screw (6) and clip (5) from shutoff valve (8).
2. Disconnect control wire (4) of heater control cable (7) from pin (3) of shutoff valve (8).
3. Loosen two clamps (2) and remove shutoff valve (8) from hoses (1).
b. Inspection
1. Connect shutoff valve (8) to two hoses (1) and tighten clamps (2).
2. Connect control wire (4) of heater control cable (7) to pin (3) of shutoff valve (8) with clip (5) and
screw (6).
FOLLOW-ON TASKS: ● Fill cooling system (para. 3-60).

● Start engine (TM 9-2320-280-10) and check shutoff valve for leaks.
10-137
TM 9-2320-280-20-3
10-84. HEATER OUTLET/lNLET PIPING MAINTENANCE

This task covers:
b. Inspection
INITIAL SETUP:
General mechanic’s tool kit: Cooling system drained as required (para. 3-60).
Manual References
TM 9-2320-280-10
TM 9-2320-280-24P
NOTE
Procedures for installing and removing inlet and outlet piping are
basically the same. This procedure covers the outlet piping.
1. Loosen clamp (9) from heater outlet hose (10) and water pump nipple (8) and disconnect outlet
hose (10).
2. Remove nut (12), washer (7), capscrew (6), and washer (7) from inlet hose clamp (5) and outlet hose
clamp (13).
3. Loosen clamp (2) and remove heater outlet hoses (3) and (10), and heater outlet tube (11) from
vehicle.
4. Loosen two clamps (4) and remove heater outlet tube (11) from heater outlet hoses (3) and (10).
5. Remove clamps (2), (4), (13), and (9) from hoses (3) and (10).
Inspect heater outlet port (1) and water pump nipple (8) for damage. Replace if damaged.
1. Install clamps (2), (4), (13), and (9) on hoses (3) and (10).
2. Connect two heater outlet hoses (3) and (10) to heater outlet tube (11) and tighten two Clamps (4).
3. Install heater outlet hoses (3) and (10) and heater outlet tube (11) between heater outlet port (1) and
water pump nipple (8).
4. Connect heater outlet hose (3) to heater outlet port (1) and tighten clamp (2).
5. Install outlet hose clamp (13) on inlet hose clamp (5) with washer (7), capscrew (6), washer (7), and
nut (12).
6. Connect heater outlet hose (10) to water pump nipple (8) and tighten clamp (9).
10-138
TM 9-2320-280-20-3
10-84
FOLLOW-ON TASKS: Q Fill cooling system (para. 3-60).

● Start engine (TM 9-2320-280-10) and check outlet piping for leaks.
10-139
TM 9-2320-280-20-3
10-85. HEATER FAN SWITCH REPLACEMENT

This task covers:
lNITIAL SETUP:
General mechanic’s tool kit Battery ground cable disconnected (para. 4-73).
Manual References
TM 9-2320-280-10
TM 9-2320-280-24P
1. Remove four capscrews (8) from instrument cluster (1) and instrument panel (6), and pull
instrument cluster (1) away from panel (6) for access to fan switch (2).
2. Remove two screws (7) from fan switch (2) and panel (6).
3. Pull fan switch (2) out from behind panel (6).
NOTE
Prior to removal, tag leads for installation.
4. Disconnect leads 399 (3), 27D (4), and 400 (5) from fan switch (2) and remove fan switch (2).
1. Connect leads 399 (3), 27D (4), and 400 (5) to fan switch (2).
2. Install fan switch (2) on panel (6) with two screws (7).
3. Install instrument cluster (1) on panel (6) with four capscrews (8).
10-140
TM 9-2320-280-20-3
I 10-85. HEATER FAN SWITCH REPLACEMENT (Cont’d)
FOLLOW-ON TASKS: ● Connect battery ground cable (para 4-73).
. Check heater fan for proper operation (TM 9-2320-280-10).
10-141
TM 9-2320-280-20-3
10-86. HEATER FAN MOTOR RESISTOR ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP
General mechanic’s tool kit Battery ground cable disconnected (para. 4-73).
Manual References
TM 9-2320-280-10
TM 9-2320-280-24P
1. Remove four capscrews (12) from instrument cluster (1) and instrument panel (2), and pull
instrument cluster (1) away from panel (2) for access to resistor assembly (5).
2. Remove two screws (11) and heater fan switch (8) from panel (2). Pull heater fan switch (8) out from
behind panel (2).
NOTE
3. Disconnect leads 399 (3) and 400 (6) from heater fan switch (8). Disconnect lead 400 (4) from harness
lead 400D (7).
4. Loosen two screws (9) and nuts (10) and remove resistor assembly (5) from panel (2).
I b. Installation I
1. Connect lead 400 (4) to harness lead 400D (7). Connect leads 400 (6) and 399 (3) to heater fan
switch (8).
2. Install resistor assembly (5) on panel (2) and tighten two screws (9) and nuts (10).
3. Install heater fan switch (8) on panel (2) with two screws (11).
10-142
TM 9-2320-280-20-3
I 10-86. HEATER FAN MOTOR RESISTOR ASSEMBLY REPLACEMENT (Cont’d)
FOLLOW-ON TASKS: ● Connect battery ground cable (para. 4-73).

● Check heater fan for proper operation (TM 9-2320-280-10).
10-143
TM 9-2320-280-20-3
10-87. HEATER ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
Four locknuts (Appendix G, Item 65) ● Battery ground cable disconnected (para. 4-73).
Nut and lockwasher assembly ● Cooling system drained as required (para. 3-60).
(Appendix G, Item 144) Q Weathercap removed (para. 3-18).

Tiedown strap (Appendix G, Item 239) ● Air cleaner assembly removed (para. 3-12).
1. Remove tiedown strap (11) from cable (12) and clamp (10). Discard tiedown strap (11).
2. Loosen clamp (10) and disconnect diverter box duct (8) from heater assembly (9).
3. Disconnect harness lead 400D (13) from heater assembly lead (14).
4. Remove nut and lockwasher assembly (18) and lead 57E (19) from heater assembly (9). Discard nut
5. Loosen two clamps (1) and disconnect heater inlet hose (2) and heater outlet hose (16) from inlet
port (3) and outlet port (15).
6. Loosen clamp (21) and remove hose (20) from clamp (21) on heater assembly (9).
7. Remove three screws (23) and washers (24) from air intake neck (22) and cowl (25). Remove
neck (22) for access to heater mounting hardware.
8. Remove four locknuts (4), washers (5), capscrews (6), and washers (5) from heater assembly (9) and
body (7). Discard locknuts (4).
9. Remove ten clips (26) from heater boot (27) and heater assembly (9).
10. Slide heater assembly (9) right and away from firewall (17) to allow heater inlet port (3) and outlet
port (15) to clear grommet openings in firewall (17) and remove heater assembly (9).
I b. Installation
I
1. Install heater assembly (9) on firewall (17) and insert heater inlet port (3) and heater outlet
port (15) through grommet openings in firewall (17).
2. Install heater boot (27) on heater assembly (9) with ten clips (26).
3. Install heater assembly (9) on body (7) with four washers (5), capscrews (6), washers (5), and
4. Install air intake neck (22) on cowl (25) with three washers (24) and capscrews (23). Tighten
5. Connect heater inlet hose (2) and heater outlet hose (16) to heater assembly (9) inlet port (3) and
outlet port (15) and tighten two clamps (1).
6. Install lead 57E (19) to heater assembly (9) with nut and lockwasher assembly (18).
7. Connect harness lead 400D (13) to heater assembly lead (14).
8. Connect diverter box duct (8) to heater assembly (9) and tighten clamp (10).
9. Install hose (20) in clamp (21) on heater assembly (9) and tighten clamp (21).
10. Install cable (12) on clamp (10) with tiedown strap (11).
10-144
TM 9-2320-280-20-3
10-87. HEATER ASSEMBLY REPLACEMENT (Cont’d) I
FOLLOW-ON TASKS: “ Install weathercap (para. 3-18).

● Install air cleaner assembly (para. 3-12).
● Fill cooling system (para. 3-60).
● Check heater assembly for proper operation (TM 9-2320-280-10).
10-145
TM 9-2320-280-20-3
1 0 - 8 8 . DEFROST CONTROL REPLACEMENT
This task covers:

INITIAL SETUP:
Tiedown strap (Appendix G, Item 239) • Hood raised and secured (TM 9-2320-280-10).
Pushnut (Appendix G, Item 170) • Engine access cover removed (para. 10-15).
a. Removal
1. Remove four capscrews (2) from instrument cluster (5) and instrument panel (3).
2. Pull instrument cluster (5) away from panel (3).
3. Remove nut (15), lockwasher (16), screw (9), clamp (14), and control cable (6) from diverter box
4. Remove pushnut (12) from control wire (13) and baffle pin (11). Discard pushnut (12).
5. Disconnect control wire (13) from baffle pin (11) on diverter box bracket (10).
6. Remove tiedown strap (18) from control cable (6) and hose clamp (17). Discard tiedown strap (18).
7. Pull control cable (6) through firewall (19) and three clamps (7) on “A” beam (8) and firewall (19).
8. Remove nut (4) from threaded shaft (1) and instrument panel (3) and pull control cable (6) through
panel (3).
b. Installation
1. Feed control cable (6) through instrument panel (3) and install threaded shaft (1) on panel (3) with
nut (4).
2. Route control cable (6) through three clamps (7) on “A” beam (8) and firewall (19).
3. Connect control wire (13) to baffle pin (11) on diverter box bracket (10) with pushnut (12).
NOT E
Control wire and knob must be pushed in, and baffle pin must be
in the upward position before securing control cable to
diverter box.
4. Install clamp (14) on control cable (6) and diverter box bracket (10) with screw (9), lockwasher (16),
and nut (15).
5. Install control cable (6) on hose clamp (17) with tiedown strap (18).
10-146 Change 1
TM 9-2320-280-20-3
I 10-88. DEFROST CONTROL REPLACEMENT (Cont’d)
FOLLOW-ON TASKS: ● Lower and secure hood (TM 9-2320-280-10).

● Install engine access cover (para. 10-15).
● Check defroster control for proper operation (TM 9-2320-280-10).
10-147
TM 9-2320-280-20-3
I 10-89. HEATER CONTROL REPLACEMENT

This task covers:
lNITIAL SETUP:
General mechanic’s tool kit: ● Hood raised and secured (TM 9-2320-280-10).
automotive (Appendix B, Item 1) ● Engine access cover removed (pars. 10-15).
Manual References
TM 9-2320-280-10
TM 9-2320-280-24P
1. Remove screw (12) and clamp (11) from cable (7) and heater shutoff valve (15).
2. Remove control wire (10) from pin (9) on heater shutoff valve (15).
3. Carefully work cable (7) through three clips (13) along “A” beam (14).
4. Remove four capscrews (2) from instrument cluster (6) and instrument panel (3).
5. Pull instrument cluster (6) away from instrument panel (3).
6. Loosen nut (4) and slide along cable (7).
7. Pull cable (7) through nut (4) and instrument panel (3).
1. Feed cable (7) through instrument panel (3) and seat threaded shaft (1) in grommet (5).
2. Place nut (4) over cable (7) and secure threaded shaft (1) on instrument panel (3) by tightening
nut (4).
3. Install instrument cluster (6) on instrument panel (3) with four capscrews (2).
4. Feed cable (7) carefully through three clips (13) along “A” beam (14).
5. Slip coiled end of control wire (10) over pin (9).
NOTE
Control wire and knob must be pushed in, and pin and lever
rotated toward heater before anchoring cable to shutoff valve.
6. With control wire (10) and knob all the way in and pin (9) moved as close to heater (8) as possible,
install cable (7) on shutoff valve (15) with clamp (11) and screw (12).
10-148
TM 9-2320-280-20-3
10-89. HEATER CONTROL REPLACEMENT (Cont’d)
FOLLOW-ON TASKS: ● Lower and secure hood (TM 9-2320-280-10).

● Install engine access cover (para. 10-15).
s Check heater control for proper operation (TM 9-2320-280-10).
10-149
TM 9-2320-280-20-3
1 0 - 9 0 . H E ATER CONTROL CABLE AND SHUTOFF V

A LVE ADJUSTMENT
This task covers:

Adjustment
INITIAL SETUP:
Lubricating oil (Appendix C, Item 32) Ensure engine is cool prior to performing this
procedure.
NOT E
Perform the following procedure if the heater temperature control
assembly is difficult to operate. The repositioning of the heater
temperature control cable and heater shutoff valve will reduce
cable bends and allow access for lubrication.
Adjustment
1. Push heater control knob (18) to “OFF’’ position.

WARNING
Ensure engine is cool prior to performing this procedure. Steam or
hot coolant under pressure can cause injury to personnel.
2. Loosen two clamps (3) on hoses (4).
3. Rotate heater shutoff valve (1) and position heater shutoff valve lever (5) in the upward position.
4. Tighten two clamps (3) on hoses (4).
5. Loosen screw (14) and clip (13) and remove cable assembly (2) from heater shutoff valve (1).
6. Remove screw (8), washer (9), clamp (10), and crankcase depression regulator valve (11) from
mounting bracket (12).
7. Install crankcase depression regulator valve (11) on mounting bracket (12) with screw (8) and washer (9).
8. Cut loop end (6) from spring wire (7). Cut as close to loop end (6) as possible.
9. Remove spring wire (7) from steel casing (16) and tube (15) by pulling heater control knob (18).
Remove any kinks in spring wire (7).
NOTE
If control cable is 47.5 in. (1207 mm) in length, perform step 10.
10. Remove a 5 in. (127.0 mm) section from steel casing (16).
11. Route steel casing (16) through clamp (20).
12. Install spring wire (7) into steel casing (16) and tube (15).
13. Position end of steel casing (16) 0.75 in. (19.0 mm) from clip (13) and install steel casing (16) on
heater shutoff valve (1) with clip (13) and screw (14).
14. Position heater control knob (18) 0.125 in. (3.18 mm) from instrument panel (17).
15. Turn spring wire (7) three turns around heater shutoff valve pin (21). Cut off any excess spring wire (7).
16. Pull out heater control knob (18) to “ON” position.
17. Apply lubricating oil to heater shutoff valve lever (5) and shutoff valve pin (21).
18. Apply lubricating oil to plunger (19).
19. Move heater control knob (18) to “OFF” and “ON” several times to distribute oil.
20. Check engine coolant level (TM 9-2320-280-10).
21. Start engine (TM 9-2320-280-10) and check heater shutoff valve (1) connections for leaks.
10-150 Change 1
TM 9-2320-280-20-3
10-90. HEATER CONTROL CABLE AND SHUTOFF VALVE ADJUSTMENT (Cont’d)
10-151
TM 9-2320-280-20-3
1 0 - 9 1 . H E ATER DUCTING REPLACEMENT
This task covers:

INITIAL SETUP:
Two locknuts (Appendix G, Item 106) • Engine access cover removed (para. 10-15).
• Front radio rack assembly removed, if equipped
(para. 12-132).
a. Removal
NOT E
• Perform steps 1 and 2 for vehicles with new configuration.
• Proceed to step 3 for vehicles with old configuration.
1. Remove two capscrews (8.1) and washers (8.2) securing two radio rack upper mounting
brackets (8.3) to plenum (7).
2. Remove nine screws (8) securing plenum (7) to “A” beam (4).
3. Remove nine screws (8), two capscrews (6), and washers (5) securing plenum (7) to “A” beam (4).
4. Disconnect connector (23) from light switch (10).
5. Remove two locknuts (25), washers (11), capscrews (12), and washers (11) securing instrument
panel (9) to firewall (24). Discard locknuts (25).
6. Remove nut (19), washer (18), capscrew (17), and washer (18) securing panel (9) and hand throttle
bracket (15) to steering column bracket (20).
7. Remove nut (13) and screw (16) securing hand throttle bracket (15) to instrument panel (9).
8. Remove screw (14) securing panel (9) to firewall (24) and pull panel (9) away from “A” beam (4)
for access to heat flex duct (1).
9. Remove clamp (2) securing heat flex duct (1) to “A” beam (4) and plenum bracket (3).
10. Remove clamp (22) securing heat flex duct (1) to steering column mount (21) and remove heat
flex duct (1).
b. Installation
1. Install heat flex duct (1) to steering column mount (21) and secure with clamp (22).
2. Secure heat flex duct (1) to “A” beam (4) and plenum bracket (3) with clamp (2).
3. Place panel (9) back to “A” beam (4). Secure panel (9) to firewall (24) with screw (14).
4. Secure panel (9) and hand throttle bracket (15) to steering column bracket (20) with washer (18),
capscrew (17), washer (18), and nut (19).
5. Secure hand throttle bracket (15) to instrument panel (9) with screw (16) and nut (13).
6. Secure panel (9) to firewall (24) with two washers (11), capscrews (12), washers (11), and locknuts (25).
7. Connect connector (23) to light switch (10).
NOT E
• Perform steps 8 and 9 for vehicles with new configuration.
• Proceed to step 10 for vehicles with old configuration.
8. Install plenum (7) on “A” beam (4) with nine screws (8).
9. Install two radio rack upper mounting brackets (8.3) to plenum (7) with two washers (8.2) and
capscrews (8.1).
10. Install plenum (7) on “A” beam (4) with nine screws (8), two washers (5), and capscrews (6).
10-152 Change 1
TM 9-2320-280-20-3
1 0 - 9 1 . H E ATER DUCTING REPLACEMENT( C o n t ’ d )
FOLLOW-ON TASKS: • Install engine access cover (para. 10-15).

• Install front radio rack assembly, if equipped (para. 12-132).
Change 1 10-153
TM 9-2320-280-20-3
1 0 - 9 2 . D I V E RTER BOX REPLACEMENT (ALL EXCEPT M998A2)
This task covers:

INITIAL SETUP:
All except M998A2 series and M1123 Lockwasher (Appendix G, Item 118)
Pushnut (Appendix G, Item 170)
Tools
General mechanic’s tool kit: Manual References
a. Removal
1. Loosen clamp (12) and disconnect heater flex duct (11) from bottom of diverter box (16).
2. Loosen clamp (15) and disconnect heater flex duct (14) from diverter box (16).
3. Remove nut (8), lockwasher (9), screw (13), and clip (10) from diverter box (16). Discard
lockwasher (9).
4. Remove pushnut (7) and disconnect cable core (6) from baffle pin (5). Discard pushnut (7).
5. Remove three screws (17) from diverter box (16), right mounting bracket (3), and “A” beam (1).
6. Pull diverter box (16) away from “A” beam (1) and loosen two clamps (4) on defroster flex ducts (2)
and remove diverter box (16).
b. Installation
1. Position diverter box (16) under “A” beam (1) and connect two defroster flex ducts (2) to diverter
box (16) and tighten clamps (4).
2. Install diverter box (16) on “A” beam (1) and right mounting bracket (3) with three screws (17).
3. Connect defroster cable core (6) to baffle pin (5) with pushnut (7).
NOT E
Control cable must be pushed in, and baffle pin must be in the
upward position before installing control cable on diverter box.
4. Install clip (10) on diverter box (16) with screw (13), lockwasher (9), and nut (8).
5. Connect heater flex duct (11) to bottom of diverter box (16) and tighten clamp (12).
6. Connect heater flex duct (14) to diverter box (16) and tighten clamp (15).
10-154 Change 1
TM 9-2320-280-20-3
1 0 - 9 2 . D I V E RTER BOX REPLACEMENT (ALL EXCEPT M998A2) (Cont'd)
Change 1 10-154.1
TM 9-2320-280-20-3
1 0 - 9 2 . 1 . D I V E RTER MANIFOLD AND HOUSING REPLACEMENT
This task covers:

INITIAL SETUP:
M997A2, M1025A2, M1035A2, M1043A2, Pushnut (Appendix G, Item 170)
M1045A2, M1097A2, M1123 Four rivets (Appendix G, Item 202.1)
a. Removal
1. Remove four screws (16) and panel assembly (15) from right mounting bracket (3) and “A” beam (1).
2. Remove four rivets (14) from manifold and housing (9) and duct (13).
3. Remove two screws (8) from manifold and housing (9) and heater (7).
4. Remove screw (6) from clip (5) and manifold and housing (9).
5. Remove pushnut (10) and disconnect defroster cable core (12) from baffle pin (11). Discard pushnut (10).
6. Pull manifold and housing (9) away from “A” beam (1) and loosen two clamps (4) securing defroster
flex ducts (2) to manifold and housing (9).
7. Remove manifold and housing (9) from heater (7).
b. Installation
1. Position manifold and housing (9) under “A” beam (1) and connect two defroster flex ducts (2) to
manifold and housing (9) with two clamps (4).
2. Connect defroster cable core (12) to baffle pin (11) and install pushnut (10).
3. Install duct (13) on manifold and housing (9) with four rivets (14).
NOTE
Ensure diverter control knob is pushed into cowl and baffle pin is in
the downward position before securing control cable to diverter box.
4. Install clip (5) on manifold and housing (9) with screw (6).
5. Install manifold and housing (9) on heater (7) with two screws (8).
6. Install panel assembly (15) on “A” beam (1) and right mounting bracket (3) with four screws (16).
10-154.2 Change 1
TM 9-2320-280-20-3
1 0 - 9 2 . 1 . D I V E RTER MANIFOLD AND HOUSING REPLACEMENT (Cont’d)
Change 1 10-155
TM 9-2320-280-20-3
1 0 - 9 3 . DEFROSTER DUCTING REPLACEMENT (ALL EXCEPT M1097A2, M1123)
This task covers:

INITIAL SETUP:
All except M1097A2, M1123 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) •Hood raised and secured (TM 9-2320-280-10).
•Engine access cover removed (para. 10-15).
a. Removal
1. Remove eight screws (6) and retainer (7) from closeout panel (5) and “A” beam (4).
2. Remove three nuts (12), washers (9), capscrews (8), washers (9), clamps (10), and cable clamp (11)
from closeout panel (5) and “A” beam (4).
3. Remove two screws (13) and closeout panel (5) from “A” beam (4).
4. Loosen clamp (2) and disconnect left flex duct (3) from left defroster nozzle (1).
5. Remove three screws (19) from diverter box (18) and “A” beam (4), and pull diverter box (18) away
from “A” beam (4) for access to right defroster nozzle (14).
6. Loosen clamp (15) and disconnect right flex duct (16) from right defroster nozzle (14).
7. Loosen two clamps (17) and disconnect left flex duct (3) and right flex duct (16) from diverter
box (18).
10-156 Change 1
TM 9-2320-280-20-3
I 10-93. DEFROSTER DUCTING REPLACEMENT (Cont’d)
10-157
TM 9-2320-280-20-3
I 10-93. DEFROSTER DUCTING REPLACEMENT (Cont’d)
b. Installation
1. Connect left flex duct (2) and right flex duct (5) to diverter box (7) and tighten two clamps (6).
2. Connect right flex duct (5) to right defroster nozzle (3) and tighten clamp (4).
3. Install diverter box (7) on “A” beam (1) with three screws (8).
4. Connect left flex duct (2) to left defroster nozzle (9) and tighten clamp (10).
5. Install closeout panel (11) retainer (13) on "A" beam (1) with eight screws (12).
6. Secure closeout panel (11) to "A" beam (1) with two screws (19).
7. Install three clamps (16) and cable clamp (17) on closeout panel (11) and “A” beam (1) with three
washers (15), capscrews (14), washers (15), and nuts (18).
10-158
TM 9-2320-280-20-3
10-93. DEFROSTER DUCTING REPLACEMENT (Cont’d)
FOLLOW-ON TASKS: ● Install engine access cover (para. 10-15).

10-159
TM 9-2320-280-20-3
1 0 - 9 4 . LEFT DEFROSTER NOZZLE REPLACEMENT
This task covers:

INITIAL SETUP:
Lockwasher (Appendix G, Item 132) • Hood raised and secured (TM 9-2320-280-10).
Two locknuts (Appendix G, Item 106) • Engine access cover removed (para. 10-15).
Adhesive sealant (Appendix C, Item 10)
a. Removal
1. Remove eight capscrews (5) and retainer (6) from closeout panel (4) and “A” beam (7).
2. Remove three nuts (20), washers (17), capscrews (16), and washers (17) from three clamps (18), cable
clamp (19), closeout panel (4), and “A” beam (7).
3. Remove three screws (21) and closeout panel (4) from “A” beam (7).
4. Loosen clamp (2.1) and disconnect defroster duct (3) from defroster nozzle (2).
5. Remove locknut (9), lockwasher (10), washer (11), and pin (14) from steering column (15) and
bracket (13), and lower steering column (15). Discard locknut (9) and lockwasher (10).
NOT E
Perform steps 5.1 and 5.2 for M1097A2 and M1123 series vehicles only.
5.1. Remove nut and lockwasher assembly (15.1), screw (15.3), and ground wire 57C (15.2) from steering
column (15).
5.2. Remove locknut (15.5), washer (15.6), capscrew (15.8), washer (15.7), and two brackets (15.4) from
steering column (15). Discard locknut (15.5).
6. Remove retaining pin (12) from defroster nozzle (2) and bracket (13).
NOT E
Note position of defroster nozzle for installation.
7. Turn defroster nozzle (2) counterclockwise and remove from “A” beam (7).
b. Installation
1. Install defroster nozzle (2) on “A” beam (7).

2. Turn defroster nozzle (2) clockwise until defroster nozzle outlets (8) align with windshield frame
louvers (1).
3. Install defroster nozzle (2) on bracket (13) with retaining pin (12).
NOT E
Perform steps 3.1 and 3.2 for M1097A2 and M1123 series vehicles only.
3.1. Install two brackets (15.4) on steering column (15) with washer (15.7), capscrew (15.8),
washer (15.6), and locknut (15.5).
3.2. Install ground wire 57C (15.2), screw (15.3), and nut and lockwasher assembly (15.1) on steering
column (15).
4. Place steering column (15) in desired position, and install on bracket (13) with pin (14), washer (11),
lockwasher (10), and locknut (9). Tighten locknut (9) to 31 lb-ft (42 N•m).
5. Apply adhesive and connect defroster duct (3) to defroster nozzle (2) and tighten clamp (2.1).
10-160 Change 1
TM 9-2320-280-20-3
1 0 - 9 4 . LEFT DEFROSTER NOZZLE REPLACEMENT (Cont'd)

6. Install retainer (6) and closeout panel (4) on “A” beam (7) with eight capscrews (5).
7. Secure closeout panel (4) to A-beam (7) with three capscrews (21).
8. Install closeout panel (4), three clamps (18), and cable clamp (19) on “A” beam (7) with three
FOLLOW-ON TASKS: • Lower and secure hood (TM 9-2320-280-10).

• Install engine access cover (para. 10-15).
Change 1 10-161/(10-162 blank)

TM 9-2320-280-20-3
1 0 - 9 4 . 1 . H E ATER NOZZLE DEFLECTOR REPLACEMENT
This task covers:

INITIAL SETUP:
M1097A2, M1123 TM 9-2320-280-24P
Tools
a. Removal
Remove capscrews (3) and (4) and nozzle deflector (2) from left duct (1).
b. Installation
Install nozzle deflector (2) on left duct (1) with capscrews (3) and (4).
Change 1 10-163
TM 9-2320-280-20-3
1 0 - 9 5 . RIGHT DEFROSTER NOZZLE REPLACEMENT
This task covers:

INITIAL SETUP:
General mechanic’s tool kit: Defroster ducting removed (para. 10-93),
automotive (Appendix B, Item 1) M1097A2 and M1123 (para. 10-96.1).
Manual References
TM 9-2320-280-24P
a. Removal
NOT E
Turn defroster nozzle (2) counterclockwise and remove from “A” beam (4).
b. Installation
Install defroster nozzle (2) on “A” beam (4) and turn defroster nozzle (2) clockwise until defroster nozzle
outlets (1) align with windshield frame louvers (3).
FOLLOW-ON TASK: Install defroster ducting (para. 10-93), M1097A2 and M1123 (para. 10-96.1).
10-164 Change 1
TM 9-2320-280-20-3
1 0 - 9 6 . H E ATER BOOT REPLACEMENT
This task covers:

INITIAL SETUP:
a. Removal
1. Remove ten clips (2) from heater boot (5) and heater assembly (1).
2. Remove six clips (4) and heater boot (5) from air duct retainer (3).
b. Installation
1. Install heater boot (5) on air duct retainer (3) with six clips (4).
2. Install heater boot (5) on heater assembly (1) with ten clips (2).
Change 1 10-164.1
TM 9-2320-280-20-3
1 0 - 9 6 . 1 . DEFROSTER DUCTING REPLACEMENT (M1097A2, M1123)
This task covers:

INITIAL SETUP:
M1097A2, M1123 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
Materials/Parts
a. Removal
1. Remove eight screws (6), retainer (7), and closeout panel (5) from “A” beam (4).
3. Remove three screws (13) from closeout panel (5) and “A” beam (4).
4. Loosen clamp (2) and disconnect left flex duct (3) from left defroster nozzle (1).
5. Remove four screws (19) and diverter cover (18) from “A” beam (4).
6. Disconnect right flex duct (15) from right defroster nozzle (14).
housing (17).
b. Installation
1. Connect left flex duct (3) and right flex duct (15) to diverter housing (17) and tighten two clamps (16).
2. Apply adhesive sealant and connect right flex duct (15) to right defroster nozzle (14).
3. Install diverter cover (18) on “A” beam (4) with four screws (19).
4. Apply adhesive and connect left flex duct (3) to left defroster nozzle (1) and tighten clamp (2).
5. Install closeout panel (5) and retainer (7) on “A” beam (4) with eight screws (6).
6. Secure closeout panel (5) to “A” beam (4) with three screws (13).
7. Install three clamps (10), cable clamp (11), and closeout panel (5) on “A” beam (4) with three
10-164.2 Change 1
TM 9-2320-280-20-3
1 0 - 9 6 . 1 . DEFROSTER DUCTING REPLACEMENT (M1097A2, M1123) (Cont'd)

Change 1 10-164.3
TM 9-2320-280-20-3
1 0 - 9 6 . 2 . H E ATER HOSE REPLACEMENT
This task covers:

INITIAL SETUP:
M1097A2, M1123 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
Materials/Parts
Adhesive (Appendix C, Item 10)
a. Removal
Disconnect heater hose (2) from left duct (1) and right duct (3), and remove heater hose (2).
b. Installation
Apply adhesive and connect heater hose (2) to left duct (1) and right duct (3).

10-164.4 Change 1
TM 9-2320-280-20-3
1 0 - 9 6 . 3 . D I V E RTER BOX COVER REPLACEMENT
This task covers:

INITIAL SETUP:
M1097A2, M1123 TM 9-2320-280-24P
Tools
a. Removal
Remove four screws (4) and diverter box cover (3) from right mounting bracket (2) and “A” beam (1).
b. Installation
Install diverter box cover (3) on right mounting bracket (2) and “A” beam (1) with four screws (4).
Change 1 10-164.5
TM 9-2320-280-20-3
1 0 - 9 6 . 4 . D I V E RTER DUCTING REPLACEMENT
This task covers:

INITIAL SETUP:
M1097A2, M1123 TM 9-2320-280-24P
Tools Manual Reference
General mechanic’s tool kit: Diverter box cover removed (para. 10-96.3).
a. Removal
Loosen clamp (1) and remove diverter ducting (2) from diverter duct (3).
b. Installation
Install diverter ducting (2) on diverter duct (3) and tighten clamp (1).
FOLLOW-ON TASK: Install diverter box cover (para. 10-96.3).
10-164.6 Change 1
TM 9-2320-280-20-3
1 0 - 9 7 . AIR DUCT ASSEMBLY REPLACEMENT
This task covers:

INITIAL SETUP:
General mechanic’s tool kit: • Arctic heater removed, if installed (para. 12-41).
automotive (Appendix B, Item 1) • Heater boot removed (para. 10-96).
Manual References
TM 9-2320-280-24P
a. Removal
Remove four speed nuts (2), screws (5), air duct retainer (1), and grille assembly (3) from body (4).
b. Installation
Install grille assembly (3) and air duct retainer (1) on body (4) with four screws (5) and speed nuts (2).
FOLLOW-ON TASKS: • Install arctic heater, if removed (para. 12-41).

• Install heater boot (para. 10-96).
Change 1 10-165
TM 9-2320-280-20-3
1 0 - 9 7 . 1 . D I V E RTER BOX REPLACEMENT (M998A2 SERIES)

This task covers:
INITIAL SETUP:
M998A2 series Two clips (Appendix G, Item 14.1)
Six rivets (Appendix G, Item 202.1)
Tools Pushnut (Appendix G, Item 170)
• Diverter box cover removed (para. 10-96.3).
Manual References • Diverter ducting removed (para. 10-96.4).
TM 9-2320-280-24P
a. Removal
1. Remove two clips (14) from transition diverter (12) and transition (13).
2. Remove two screws (8) from diverter (9) and heater (7).
3. Remove screw (5) and clamp (4) from diverter (9).
4. Remove pushnut (11) and disconnect cable core (6) from baffle pin (10). Discard pushnut (11).
5. Pull diverter (9) away from “A” beam (1) and loosen two clamps (3) on defroster flex ducts (2) and
remove diverter (9).
6. Remove four rivets (21) and transition diverter (15) from diverter (17).
7. Remove louver (16) from transition diverter (15).
8. Remove two rivets (19), flap (20), and bracket (18) from diverter (17).
b. Installation
1. Install flap (20) and bracket (18) on diverter (17) with two rivets (19).
2. Install louver (16) on transition diverter (15).
3. Install transition diverter (15) on diverter (17) with four rivets (21).
4. Position diverter (9) under “A” beam (1), connect two defroster flex ducts (2) to diverter (9), and
tighten clamps (3).
5. Connect defroster cable core (6) to baffle pin (10) and install pushnut (11).
6. Install transition diverter (12) on transition (13) with two clips (14).
NOTE
upward position before securing control cable to diverter box.
7. Install clamp (4) on diverter (9) with screw (5).
8. Install diverter (9) on heater (7) with two screws (8).
10-166 Change 1
TM 9-2320-280-20-3
1 0 - 9 7 . 1 . D I V E RTER BOX REPLACEMENT (M998A2 SERIES) (Co n t ’ d )
FOLLOW-ON TASKS: • Install diverter ducting (para. 10-96.4).

• Install diverter box cover (para. 10-96.3).
Change 1 10-166.1/(10-166.2 blank)

TM 9-2320-280-20-3
10-98. “A” PILLAR FORMER ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
M998, M998A1, M1035, M1035A1, M1035A2, TM 9-2320-280-10
M1037, M1038, M1038A1, M1042 TM 9-2320-280-24P
General mechanic’s tool kit: Soft top removed (TM 9-2320-280-10).
Materials/Parts
Wellnut (Appendix G, Item 244)
1. Remove thirteen screws (3) and “A” pillar former (2) from “A” pillar (1).
2. Clean weatherstrip from “A” pillar (1).
3. Inspect wellnut (4) for damage. Replace if damaged.
b. Installation
1. Peel backing paper from “A” pillar former (2).
2. Install “A” pillar former (2) on “A” pillar (1) with thirteen screws (3).
FOLLOW-ON TASK: Install soft top (TM 9-2320-280-10).
10-167
TM 9-2320-280-20-3
1 0 - 9 9 . “C” PILLAR REPLACEMENT
This task covers:

INITIAL SETUP:
M998, M998A1, M1035, M1035A1, Four locknuts (Appendix G, Item 58)
M1038, M1038A1 Four locknuts (Appendix G, Item 107.1)
Eight rivets (Appendix G, Item 195.1)
Tools
automotive (Appendix B, Item 1) TM 9-2320-280-10
TM 9-2320-280-24P
Equipment Condition
Soft top removed (TM 9-2320-280-10).
a. Removal
1. Remove four locknuts (6), washers (5), capscrews (4), washers (5), eight rivets (2), and two braces (3)
from “C” pillar (1) and wheelhouses (7). Discard locknuts (6).
2. Remove four locknuts (8), washers (9), capscrews (11), washers (9), two plates (10), and “C” pillar (1)
from wheelhouses (7). Discard locknuts (8).
3. Inspect rivnut (12) for damage. Replace if damaged.
b. Installation
1. Install “C” pillar (1) on wheelhouses (7) with two plates (10), four washers (9), capscrews (11), washers (9),
and locknuts (8). Tighten capscrews (11) to 6 lb-ft (8 N•m).
2. Install two braces (3) on wheelhouses (7) and “C” pillar (1) with four washers (5), capscrews (4),
washers (5), locknuts (6), and eight rivets (2).
FOLLOW-ON TASK: Install soft top (TM 9-2320-280-10).
10-168 Change 1
TM 9-2320-280-20-3
10-100. REAR BOW PIVOT BRACKET REPLACEMENT

Tbis task covers:
INITIAL SETUP:
M998, M998A1, M1035, M1035A1, M1035A2, TM 9-2320-280-10
M1038. M1038A1. M1097. M1097A1. TM 9-2320-280-24P
M1097A2
Equipment Condition
Tools Bows removed (TM 9-2320-280-10).
Materials/Parts
Remove two locknuts (6), washers (5), capscrews (1), washers (2), bow pivot bracket (3), and plate (7)
from body (4). Discard locknuts (6).
Install plate (7) and bow pivot bracket (3) on body (4) with two washers (2), capscrews (1), washers (5),
and locknuts (6). Align bow pivot bracket (3) flush with side of body (4) and tighten two capscrews (1) to
6 lb-ft (8 N.m).
FOLLOW-ON TASK: Install bows (TM 9-2320-280-10).
10-169
TM 9-2320-280-20-3
10-101. SOFT TOP DOOR HINGE REPLACEMENT

This task covers:
INITIAL SETUP:
M998, M998A1, M1035, M1035A1, M1035A2, TM 9-2320-280-10
M1037. M1038, M1038A1, M1042, M1097, TM 9-2320-280-24P
M1097A1, M1097A2
Equipment Condition
Tools Soft top door removed (TM 9-2320-280-10).
Materials/Parts
Two nut and lockwasher assemblies
(Appendix G, Item 144)
NOTE
Doorstrap brackets are attached to upper hinges only. This

procedure covers the left door upper hinge.
I a. Removal
Remove two nut and lockwasher assemblies (2), screws (5), hinge (4), and bracket (1) from
door (3). Discard nut and lockwasher assemblies (2).
I b. Installation
Install hinge (4) and bracket (1) on door (3) with two screws (5) and nut and lockwasher assemblies (2).
Tighten nut and lockwasher assemblies (2) to 6 lb-ft (8 N=m).
10-170
TM 9-2320-280-20-3
10-101. SOFT TOP DOOR HINGE REPLACEMENT (Cont’d)
FOLLOW-ON TASKS: ● Install door (TM 9-2320-280-10).

● Adjust soft top door (para. 10-102).
10-171
TM 9-2320-280-20-3
1 0 - 1 0 2 . SOFT TOP DOOR ADJUSTMENT
This task covers:

Adjustment
INITIAL SETUP:
M998, M998A1, M1035, M1035A1, M1035A2, One mechanic
M1037, M1038, M1038A1, M1042, M1097, One assistant
M1097A1, M1097A2, M1123
Manual References
Tools TM 9-2320-280-10
Adjustment
1. Open and close door (1) to check fit of door seal (2) to body (3). Door seal (2) should fit inside and
contact door outline on body (3).
2. For vertical and horizontal adjustment of door (1), loosen four screws (4) on two hinges (5) and
door (1). Slide door (1) to fit door outline on body (3). Hold door (1) in position, and tighten four
screws (4) on two door hinges (5) and door (1).
NOT E
If additional vertical adjustment is needed, follow step 3. If no
additional vertical adjustment is needed, go to step 4.
3. For additional vertical adjustment of door (1), remove door (1) from body (3) (TM 9-2320-280-10).
Loosen four capscrews (7) on two body hinge mounts (6) and body (3) and slide body hinge
mounts (6) up or down for adjustment. Hold body hinge mounts (6) in position, and tighten four
capscrews (7) to 8 lb-ft (11 N•m). Install door (TM 9-2320-280-10).
4. For in and out adjustment of door (1), loosen two capscrews (8) on striker (10) and
“B” pillar (11). With door (1) closed and door seal (2) pressed against body (3), slide striker (10)
against inner door handle latch (9) and tighten two capscrews (8). Open door (1) and tighten two
capscrews (8) to 15 lb-ft (20 N•m).
5. Close door (1) and check for fit of door seal (2) to door outline on body (3) and inner door handle
latch (9) operation. Readjust door (1) if necessary.
10-172 Change 1
TM 9-2320-280-20-3
1 0 - 1 0 2 . SOFT TOP DOOR ADJUSTMENT (Cont'd)
Change 1 10-172.1
TM 9-2320-280-20-3
1 0 - 1 0 2 . 1 . SOFT TOP DOOR HANDLE REPA I R
This task covers:

b. Repair
INITIAL SETUP:
M998, M998A1, M1035, M1035A1, M1035A2, TM 9-2320-280-24P
M1037, M1038, M1038A1, M1042, M1097,
M1097A1, M1097A2, M1123
Tools
a. Removal
1. Remove screw (5), inner (4) and outer (1) door handles, washer (7), and spring (6) from door (3).
2. Remove insert (2) from outer door handle (1) if present.
b. Repair
1. Drill 0.250-in. (6.35 mm) diameter hole through outer door handle (1).
NOTE
Countersink hole deep enough so screw is flush with surface of
handle.
2. Using a 0.500-in. (12.7 mm) diameter drill bit, countersink outer handle (1).
CAUTION
Use tape or drill stop to ensure the proper depth is not exceeded
when counterboring, or inner door handle may be damaged.
3. Counterbore inner door handle (4) to 0.238-in. (6.04 mm) diameter, 0.531-in. (13.49 mm) depth.
10-172.2 Change 1
TM 9-2320-280-20-3
1 0 - 1 0 2 . 1 . SOFT TOP DOOR HANDLE REPA I R ( C o n t ' d )
Change 1 10-172.3
TM 9-2320-280-20-3
1 0 - 1 0 2 . 1 . SOFT TOP DOOR HANDLE REPAIR (C o n t ’ d )
c. Installation
1. Install two nuts (5), washers (3), and insert (2) on screw (4).
2. Install insert (2) with screw (4) into inner handle (1). Seat bottom washer (3) against handle
surface (1).
3. Loosen two nuts (5) and remove screw (4), two nuts (5), and washers (3) from insert (2).
4. Assemble inner handle (1), washer (7), spring (6), and outer handle (8) with screw (4).
5. Measure length of screw (4) from insert (2).
6. Remove screw (4) and cut to measurement.
7. Install washer (7), outer handle (8), spring (6), and inner handle (1) on door (9) with screw (4).
8. Check door handle for proper operation.
10-172.4 Change 1
TM 9-2320-280-20-3
1 0 - 1 0 2 . 1 . SOFT TOP DOOR HANDLE REPA I R ( C o n t ' d )
Change 1 10-173
TM 9-2320-280-20-3
10-103. SOFT TOP DOOR STRIKER REPLACEMENT

This task covers:
INITIAL SETUP:
M998, M998A1, M1035, M1035A1, M1035A2, TM 9-2320-280-24P
M1037, M1038, M1038A1, M1042, M1097,
M1097A1, M1097A2
Tools
General mechanic's tool kit
NOTE
Front door strikers are installed with washers and capscrews.
Rear door strikers are installed with star washers and capscrews.
This procedure covers a front door striker.
Remove two nuts (4), washers (2), capscrews (1), washers (2), and door striker (3) from body (5).
Install door striker (3) on body (5) with two washers (2), capscrews (1), washers (2), and nuts (4).
Tighten capscrews (1) to 15 lb-ft (20 N-m).
FOLLOW-ON TASK: Adjust soft top door (para. 10-102).
10-174
TM 9-2320-280-20-3
1 0 - 1 0 4 . SOFT TOP REPA I R
This task covers:

a. Inspection and Cleaning d. Soft Top Window Zipper Repair (Temporary)
b. Soft Top Material Repair e. Soft Top Canvas Repair
c. Soft Top Window Repair
INITIAL SETUP:
Applicable Models Manual Reference
M998, M998A1, M1035, M1035A1, M1035A2, FM 10-16
M1037, M1038, M1038A1, M1042, M1097, TM 9-2320-280-10
M1097A1, M1097A2, M1123 TM 9-2320-280-24P
General mechanic’s tool kit: Soft top enclosure removed, as required
Materials/Parts
Sealing compound (Appendix C, Item 42)
Hook and pile material (Appendix C, Item 52)
Two plastic sheets (Appendix D, Figure D-64)
Green plastic canvas
(Appendix D, Figure D-114)
Six grommets (Appendix G, Item 52.2)
Six stud turnbuttons (Appendix G, Item 243.3)
Twelve clinch plate turnbuttons
(Appendix G, Item 243.2)
a. Inspection and Cleaning
1. Inspect soft top doors and tops for pin holes and leaks around the seam areas.
2. Using soapy water solution and stiff brush, clean area to be sealed on the outer side of the canvas.
Allow to dry.
b. Soft Top Material Repair
1. Apply sealing compound to cleaned area where leak occurred. Ensure sealing compound is pressed
into stitching of seams.
2. Allow 20 minutes for sealing compound to cure.
Change 1 10-175
TM 9-2320-280-20-3
1 0 - 1 0 4 . SOFT TOP REPAIR (Cont’d)
c. Soft Top Window Repair
NOT E
The use of pressure-sensitive, adhesive-coated plastic sheets for
temporary repair of small window cracks and holes should only be
utilized if it does not hinder operator’s vision. If damaged area is
large enough so that plastic sheets will hinder operator’s vision,
door assembly should be replaced.
1. Ensure damaged area of window (1) is clean and dry.
2. Peel backing off plastic sheet (2) and apply to damaged area of window (1).
3. Peel backing off plastic sheet (3) and apply to other side of damaged area of window (1).
d. Soft Top Window Zipper Repair (Temporary)

NOTE
Use hook and pile material as a temporary measure to secure
window with failed zipper until zipper or door can be replaced.
1. Apply half (5) of the self-adhesive hook and pile material on inside of door (4) around window (1).
2. Put mating half (6) of hook and pile material on window (1). Apply strips as required to firmly
secure window.
10-176 Change 1
TM 9-2320-280-20-3
e. Soft Top Canvas Repair
NOT E
Since these procedures are a reinforcement guide, you can modify
them to meet individual needs. These reinforcement procedures
are helpful because:
• The securing straps reinforce the enclosure and reduce its
“ballooning” action.
• The extra wear, damage, and holes in the enclosure are reduced.
• Any enclosure can be returned to a serviceable condition at a
significantly lower cost than replacing the enclosure.
1. Secure six grommets and stud turnbuttons to canvas straps (2), (3), and (4) using twelve clinch plate
turnbuttons, follow procedures found in FM 10-16, General Fabric Repair.
2. Sew the eight canvas straps (2), (3), and (4) to inside of soft top enclosure (1). Follow procedures for
sewing on straps as found in FM 10-16, General Fabric Repair. Attach straps in the following
locations:
(a) Strap A (4) – On top front corners of soft top enclosure (1).
(b) Strap B (3) – Where the corners of second and third bows make contact with the enclosure (1).
(c) Strap C (2) – On the soft top enclosure (1) where second and third bows make contact with soft
top enclosure (1).
Change 1 10-176.1
TM 9-2320-280-20-3
FOLLOW-ON TASK: Install soft top enclosure, as required, (TM 9-2320-280-10), ensuring straps are
fastened around bows.
10-176.2 Change 1
TM 9-2320-280-20-3
10-105. “C” PILLAR REINFORCEMENT BRACKETS INSTALLATION

This task covers:
Installation
lNITIAL SETUP:
Manual Reference
TM 43-0139
Materials/Parts
Two brackets (Appendix D, Fig. D-89) Equipment Condition
Two locknuts (Appendix G, Item 95) Soft top removed as required (TM 9-2320-280-10).
Eight rivets (Appendix G, Item 200)
NOTE
● The following procedure can be performed to prevent fatigue
cracking of the “C” pillar mount brackets. Installation is at
commander’s discretion.
s For instructions on replacement of rivets, refer to para. 10-66.
1. Using 0.187-inch drill bit, remove rivet (5) from wheelhousing (4).
2. Scribe two reference lines (3) on “C” pillar (2).
3. Align reinforcement bracket (1) with reference lines (3) on “C” pillar (2).
4. Scribe hole location (5) on wheelhousing (4) onto reinforcement bracket (1).
5. Using reinforcement bracket as template, drill four 0.187-inch diameter holes through reinforcement
bracket (1) and “C” pillar (2). Remove bracket (1).
6. Using 0.281-inch drill bit, enlarge hole (5) in wheelhousing (4).
7. Using hole location marked in step 4, drill 0.281-inch diameter hole in reinforcement bracket (1).
8. Spot paint reinforcement bracket (refer to TM 43-0139).
10-177
TM 9-2320-280-20-3
10-105. “C” PILLAR REINFORCEMENT BRACKETS INSTALLATION
9. Install reinforcement bracket (1) on “C” pillar (2) with four rivets (3).
10. Align mount hole (7) in reinforcement bracket (1) and hole in wheelhousing (4) and install
washer (6), screw (8), washer (6), and locknut (5).
11. Spot paint as necessary (refer to TM 43-0139).
FOLLOW-ON TASK: Install soft top as required (TM 9-2320-280-10).
10-178
TM 9-2320-280-20-3
Section III. WINCH MAINTENANCE
1 0 - 1 0 6 . WINCH MAINTENANCE TASK SUMMARY
TASK PAGE
PROCEDURES
PARA. NO.
10-107. 6,000 Lb Winch Replacement 10-180
10-108. 9,000 Lb Winch Replacement 10-184
10-108.1. 10,500 Lb Hydraulic Winch and Brackets Replacement 10-186.2
10-109. Winch Control Box Replacement 10-188
10-110. Winch Cable Replacement 10-190
10-110.1. Hydraulic Winch Cable Replacement 10-190.2
10-111. Winch Vent Line Replacement 10-192
10-112. Fairlead Roller Bracket Assembly Replacement 10-193
10-113. 10,500 Lb Winch Hydraulic Hose Replacement 10-194
Change 1 10-179
TM 9-2320-280-20-3
10-107. 6,000 LB. WINCH REPLACEMENT

This task covers:
INITIAL SETUP:
M1026, M1026A1, M1036, M1038, M1038A1, One mechanic
M1042, M1044, M1044A1, M1046, M1046A1 One assistant

TM 9-2320-280-24P
Equipment Condition
Materials/Parts
. Winch cable removed (para. 10-110).
Four lockwashers (Appendix G, Item 108) ● Battery ground cable disconnected (para. 4-73).
Three tiedown straps (Appendix G, Item 243) ● Hood raised and secured (TM 9-2320-280-10).
Nut and lockwasher assembly
(Appendix G, Item 144) General Safety Instructions
Winch must be supported during removal and
installation.
WARNING
Winch must be supported during removal and installation. Failure
to support winch may result in injury to personnel or damage to
equipment.
1. Remove nut (9) and lockwasher (10) and disconnect lead 7 (11) from starter terminal (8). Discard
lockwasher (10).
2. Remove nut (7) and lockwasher (6) and disconnect lead 6 (4) from starter terminal (5). Discard
lockwasher (6).
3. Remove nut and lockwasher assembly (1) and clamp (3) from oil pan bracket screw (2). Discard nut
4. Remove two capscrews (18), clamp (23), and bracket (19) from airlift bracket (20).
5. Remove nut (12), lockwasher (13), capscrew (15), and clamp (14) from frame bracket (29). Discard
lockwasher (13). Pull cables (27) to front of vehicle.
6. Disconnect cable (35) from control cable (36) in winch control box (37) and remove grommet (34) and
cable (35) from control box (37).
7. Disconnect vent line (24) from fitting (25) on winch (33) and remove three tiedown straps (26) from
vent line (24) and power cables (27). Discard tiedown straps (26).
8. Remove four capscrews (30), washers (31), and nuts (32) from winch (33) and front bumper (38).
Lower and remove winch (33) and power cables (27) from vehicle.
9. Measure length of power cables (27) from clamp (28) on winch (33) to clamp (21) on bracket (19) and record.
Remove nut (17), lockwasher (16), capscrew (22), clamp (21), and bracket (19) from power cables (27).
10-180
TM 9-2320-280-20-3
10-107
10-181
TM 9-2320-280-20-3
10-107. 6,000 LB. WINCH REPLACEMENT (Cont’d)
b. Installation
1. Install clamp (8) on power cables (15) at same distance from clamp (17) on winch (16) that was
recorded in removal.
2. Install clamp (8) and bracket (6) on power cables (15) with capscrew (9), lockwasher (3), and nut (4).
3. Install winch (16) on front bumper (29) with four nuts (23), washers (22), and capscrews (21).
4. Route cable (24) through opening (28) in control box (27) and connect to control cable (26). Install
grommet (25) in opening (28).
5. Route power cables (15) in approximate mounting location in vehicle.
6. Install lead 7 (40) on starter terminal (37) with lockwasher (39) and nut (38). Tighten nut (38) to
15 lb-ft (20 N.m).
25 lb-ft (34 N9m).
8. Install clamp (32) and power cables (15) on oil pan bracket screw (31) with nut and lockwasher
assembly (30).
9. Install clamp (10) on power cables (15) and airlift bracket (7) with capscrew (11).
10. Install bracket (6) on airlift bracket (7) with capscrew (5).
11. Install clamp (1) on power cables (15) and frame bracket (18) with capscrew (2), lockwasher (20), and nut (19).
12. Connect vent line (12) to fitting (13) on winch (16). Install vent line (12) on power cables (15) with
three tiedown straps (14).
10-182
TM 9-2320-280-20-3
I 10-107. 6,000 LB. WINCH REPLACEMENT (Cont’d)

● Install winch cable (para. 10-110).
10-183
TM 9-2320-280-20-3
I 10-108. 9,000 LB. WINCH REPLACEMENT

This task covers:
INITIAL SETUP:
M997A2, M1025A2, M1035A2, M1043A2, TM 9-2320-280-10
M1045A2, M1097A2 TM 9-2320-280-24P
General mechanic’s tool kit: . Battery ground cables disconnected (para. 4-73).
automotive (Appendix B, Item 1) . Hood raised and secured (TM 9-2320-280-10).
l Engine right splash shield removed (para. 10-20).
Materials/Parts
Four lockwashers (Appendix G, Item 108) General Safety Instructions
Four tiedown straps (Appendix G, Item 243) Winch must be supported during removal and
Nut and lockwasher assembly installation.
Personnel Required
One mechanic
One assistant
WARNING
Winch must be supported during removal and installation, Failure to support
winch may result in injury to personnel or damage to equipment.
1. Remove nut (9) and lockwaaher (10) and disconnect lead 7 (11) from starter terminal (8). Discard
lockwaaher (10).
2. Remove nut (7) and lockwasher (6) and disconnect lead 6 (4) from starter terminal (5). Discard lockwasher (6).
3. Remove nut and lockwasher assembly (1) and clamp (3) from oil pan bracket screw (2). Discard nut and
lockwasher assembly (1).
4. Remove two capscrews (18), clamp (23), and bracket (19) from airlift bracket (20).
5. Remove nut (12), lockwasher (13), capecrew (15), and clamp (14) from frame bracket (29). Discard
lockwasher (13).
6. Disconnect vent line (24) from fitting (25) on winch (30) and remove four tiedown straps (26) and
vent line (24) from power cables (27). Pull cables (27) to front of vehicle and discard tiedown
straps (26).
7. Remove four retaining rings (35), two shafts (32), and rollers (34) from fairlead roller bracket (33).
Pull cable (38) through bumper (31).
8. Remove two capscrews (36), washers (37), and fairlead roller bracket (33) from bumper (31).
9. Remove two capscrews (36) and washers (37) from winch (30) and front bumper (31). Lower and remove
winch (30) and power cables (27) from vehicle.
10. Measure length of power cables (27) from clamp (28) on winch (30) to clamp (21) on bracket (19) and
record. Remove nut (17), lockwasher (16), capscrew (22), clamp (21), and bracket (19) from power
cables (27). Discard lockwasher (16).
10-184
TM 9-2320-280-20-3
I 10-108. 9,000 LB. WINCH REPLACEMENT (Cont’d)
10-185
TM 9-2320-280-20-3
10-108. 9,000 LB. WINCH REPLACEMENT (Cont’d) I

b. Installation I
1. position clamp (8) on power cables (15) at same distance from clamp (17) On winch (16) that was
recorded in removal.
2. Install clamp (8) on power cables (15) and bracket (6) with capscrew (9), lockwasher (3), and nut (4).
3. Install winch (16) on bumper (21) with two washers (27) and capscrews (26). Tighten capscrews (26)
to 35 lb-ft (47 Nom).
4. Install fairlead roller bracket (23) on bumper (21) and winch (16) with two washers (27) and
capscrews (26). Feed cable (28) through bumper (21) and bracket (23). Tighten capscrews (26) to
35 lb-ft (47 N~m).
5. Install two rollers (24) and shafts (22) on fairlead roller bracket (23) with four retaining rings (25).
6. Route power cables (15) in approximate mounting location in vehicle.
15 lb-ft (20 N.m).
25 lb-ft (34 N.m).
9. Install clamp (30) and power cables (15) on oil pan bracket screw (’29) with nut and lockwasher
assembly (39).
10. Install clamp (10) on power cables (15) and airlift bracket (7) with capscrew (11).
11. Install bracket (6) on airlift bracket (7) with capscrew (5).
12. Install clamp (1) on power cables (15) and frame bracket (18) with capscrew (2), lockwasher (20), and nut (19).
13. Connect vent line (12) to fitting (13) on winch (16). Install vent line (12) on power cables (15) with four
tiedown straps (14).
10-186
TM 9-2320-280-20-3
1 0 - 1 0 8 . 9,000 LB WINCH REPLACEMENT (Cont'd)
FOLLOW-ON TASKS: • Install engine right splash shield (para. 10-20).

• Connect battery ground cables (para. 4-73).
Change 1 10-186.1
TM 9-2320-280-20-3
1 0 - 1 0 8 . 1 . 10,500 LB HYDRAULIC WINCH AND BRACKETS REPLACEMENT

This task covers:
a. Winch Removal c. Brackets Removal
b. Winch Installation d. Brackets Installation
INITIAL SETUP:
All vehicles except M996, M996A1, M997, • Parking brake applied (TM 9-2320-280-10).
M997A1, M997A2, M1035, M1035A1, • Battery ground cable disconnected (para. 4-73).
M1035A2 • Underbody protection kit removed (if applicable)
(para. 12-186).
Tools • Brake protection guards removed (if applicable)
General mechanic’s tool kit: (para. 7-8.1).
automotive (Appendix B, Item 1) • Hydraulic hoses disconnected from inlet and
outlet ports (para. 12-193).
Material/Parts
Six locknuts (Appendix G, Item 66) General Safety Instructions
Four locknuts (Appendix G, Item 70) Support winch and bumper during winch
Two locknuts (Appendix G, Item 79) replacement.
Manual References
TM 9-2320-280-10
TM 9-2320-280-24P
.WARNING.
Winch and bumper must be supported with a floor jack during winch
replacement. Failure to support winch may result in injury to personnel or
NOTE
Tag leads prior to removal.
a. Winch Removal
1. Remove leads (1) and (2) on controller plug harness (6) from leads (3) and (4) on winch (5).
2. Remove four locknuts (7), washers (8), screws (11), washers (8), and two tow brackets (10) from
winch and bumper assembly (9) and brackets (15). Discard locknuts (7).
3. Remove two locknuts (12), washers (13), and winch and bumper assembly (9) from left and right
lower control arm screws (14). Discard locknuts (12).
b. Winch Installation
1. Install winch and bumper assembly (9) on left and right lower control arm screws (14) with two
washers (13) and locknuts (12). Do not tighten locknuts (12).
2. Install winch and bumper assembly (9) and two tow brackets (10) on brackets (15) with four
washers (8), screws (11), washers (8), and locknuts (7).
3. Tighten locknuts (12).
4. Install leads 785C (3) and 785A (4) on winch (5) to leads 785C (2) and 785A (1) on controller plug
harness (6).
10-186.2 Change 1
TM 9-2320-280-20-3
1 0 - 1 0 8 . 1 . 10,500 LB HYDRAULIC WINCH AND BRACKETS REPLACEMENT (C

ont’d)
Change 1 10-186.3
TM 9-2320-280-20-3

ont’d)
NOTE
• Brackets may not require replacement. Replace brackets only
when damaged.
• The left and right side brackets are removed the same. This
procedure covers the right side.
c. Brackets Removal
Remove three locknuts (7), washers (4), screws (5), washers (4), bracket (3), washer (2), and washer (1)
from frame (6). Discard locknuts (7).
d. Brackets Installation
Install washer (1), washer (2), and bracket (3) on frame (6) with three washers (4), screws (5), washers
(4), and locknuts (7). Tighten locknuts (7) to 189 lb-ft (256 N•m).
10-186.4 Change 1
TM 9-2320-280-20-3

ont’d)
FOLLOW-ON TASKS: • Connect hydraulic hoses to inlet and outlet ports (para. 12-193).
• Install brake protection guards (if applicable) (para. 7-8.1).
• Install underbody protection kit (if applicable) (para. 12-186).
• Connect battery ground cable (para. 4-73).
• Bleed power steering system (para. 8-29).
Change 1 10-187
TM 9-2320-280-20-3
10-109. WINCH CONTROL BOX REPLACEMENT

I
This task covers:
lNITIAL SETUP:
M1026, M1026A1, M1036, M1038, M1038A1, Lockwasher (Appendix G, Item 124)
M1042, M1044, M1044A1, M1046, M1046A1
Manual References
Tools TM 9-2320-280-24P
automotive (Appendix B, Item 1) Battery ground cable disconnected (para. 4-73).
a. Removal
1. Open winch control box (12) and pull control cable (8) out.
2. Remove capscrew (9), clamp (10), lockwasher (2), and nut (1) from control cable (8) and control box (12).
3. Disconnect control cable (8) from cable (11) and remove control cable (8) from control box (12).
4. Remove two nuts (6), wisher (5), capscrews (4), washers (5), and control box (12) from mounting
bracket (7).
5. Slide cable (11) and grommet (3) out of control box (12).
1. Push cable (11) and grommet (3) into control box (12).
2. Install control box (12) on mounting bracket (7) with two washers (5), capscrews (4), washers (5),
and nuts (6). Tighten nuts (6) to 90 lb-ft (122 N~m).
3. Connect control cable (8) to cable (11).
4. Install control cable (8) on control box (12) with capscrew (9), clamp (10), lockwasher (2), and nut (1).
Tighten nut (1) to 6 lb-ft (8 N.m). Close and secure control box (12).
10-188
TM 9-2320-280-20-3
10-109. WINCH CONTROL BOX REPLACEMENT (Cont’d) I
FOLLOW-ON TASK: Connect battery ground cable (para. 4-73).
10-189
TM 9-2320-280-20-3
10-110. WINCH CABLE REPLACEMENT

This task covers:
lNITIAL SETUP:
M997A2, M1025A2, M1026, M1026A1, One mechanic
M1035A2, M1036, M1038, M1038A1, M1042, One assistant
M1043A2, M1044, M1044A1, M1045A2,
M1046, M1046A1, M1097A2 Manual References
TM 9-2320-280-10
Tools TM 9-2320-280-24P
automotive (Appendix B, Item 1) General Safety Instruction
Materals/Parts Wear leather gloves when handling winch cable.
WARNING
Gloves must be worn whenever handling winch cable. Severe
injury may. result.
a. Removal
1. Unwind winch cable (2) from drum assembly (1) (TM 9-2320-280-10).
NOTE
Proceed to step 4 for 9,000 lb. winch cable.
2. Remove capscrew (5) and winch cable (2) from drum assembly (1).
3. Loosen and remove clamp (3) and hook (4) from winch cable (2).
4. Remove cotter pin (6), clevis pin (8), and hook (7) from winch cable (2). Discard cotter pin (6).
b. Installation
NOTE
l Install thimble on winch cable to keep wires from shearing or
breaking. Refer to appendix D, fig. D-91 for instructions,
Perform step 1 for 9,000 lb. winch cable. Proceed to step 2 for
6,000 lb. winch cable.
1. Install hook (7) on winch cable (2) with clevis pin (8) and cotter pin (6).
2. Install clamp (3) and hook (4) on winch cable (2) and tighten clamp (3).
3. Install winch cable (2) on drum assembly (1) with capscrew (5).
CAUTION
. The winch cable must be spooled on the drum according to the
direction of rotation label on the winch or the brake will not
function.
l Winch cable must be installed on drum under a load of at least
500 lbs (227 kg) or outer wraps will draw into inner wraps and
damage winch cable.
4. Rewind winch cable (2) (TM 9-2320-280-10).
10-190
TM 9-2320-280-20-3
1 0 - 1 1 0 . WINCH CABLE REPLACEMENT (Cont'd)
FOLLOW-ON TASKS: • Lubricate winch cable (TM 9-2320-280-10).

• Check winch for proper operation (TM 9-2320-280-10).
Change 1 10-190.1
TM 9-2320-280-20-3
1 0 - 1 1 0 . 1 . HYDRAULIC WINCH CABLE REPLACEMENT
This task covers:

INITIAL SETUP:
All vehicles except M996, M996A1, M997, TM 9-2320-280-10
M997A1, M997A2, M1035, M1035A1, TM 9-2320-280-24P
M1035A2
Tools Wear leather gloves when handling winch cable.
Personnel Required
One mechanic
One assistant
WARNING
Gloves must be worn whenever handling winch cable. Severe
injury may result.
a. Removal
1. Unwind winch cable (4) from drum assembly (1) (TM 9-2320-280-10).
2. Remove screw (2), clamp (3), and cable (4) from drum assembly (1).
3. Loosen clamp (5) and remove clamp (5) and hook (6) from cable (4).
b. Installation
NOTE
Install thimble on winch cable to keep wires from shearing or
breaking. Refer to appendix D, fig. D-91 for instructions.
1. Install clamp (5) and hook (6) on winch cable (4) and tighten clamp (5).
2. Install winch cable (4) on drum assembly (1) with clamp (3) and screw (2).
3. Wind winch cable (4) on drum assembly (1) (TM 9-2320-280-10).
FOLLOW-ON TASKS: • Lubricate winch cable (TM 9-2320-280-10).

• Check winch for proper operation (TM 9-2320-280-10).
10-190.2/(10-191 blank) Change 1

TM 9-2320-280-20-3
10-111. WINCH VENT LINE REPLACEMENT

This task covers:
lNITIAL SETUP:
M997A2, M1025A2, M1026, M1026A1, TM 9-2320-280-10
M1035A2, M1036, M1038, M1038A1, M1042, TM 9-2320-280-24P
M1043A2, M1044, M1044A1, M1045A2,
M1046, M1046A1, M1097A2 Equipment Condition
l Hood raised and secured (TM 9-2320-280-10).
Tools l Engine right splash shield removed (para. 10-20).

Materials/Parts
Four tiedown straps (Appendix G, Item 243)
I a Removal I
1. Disconnect vent line (2) from winch fitting (4).
2. Remove three tiedown straps (5) and tiedown strap (6) (9,000 lb. winch only) from vent line (2) and
cables (1). Discard tiedown straps (5) and (6).
3. Disconnect vent line (2) from tee fitting (3) and remove vent line (2).
I b. Installation
1. Connect vent line (2) to tee fitting (3) and winch fitting (4).
2. Install vent line (2) on cables (1) with tiedown strap (6) (9,000 lb. winch only) and three tiedown
straps (5).
FOLLOW-ON TASK: “ Loawer and secure hood (TM 9-2320-280-10).

l Install engine right splash shield (para. 10-20).
10-192
TM 9-2320-280-20-3
1 0 - 1 1 2 . FAIRLEAD ROLLER BRACKET ASSEMBLY REPLACEMENT
This task covers:

INITIAL SETUP:
Applicable Models General Safety Instructions
M997A2, M1025A2, M1035A2, M1043A2, Winch must be supported during removal and
M1045A2, M1097A2 installation.
Tools
WARNING
Winch must be supported during removal and installation. Failure
to support winch may result in injury to personnel or damage to
equipment.
a. Removal
1. Remove four retaining rings (6), two shafts (5), and rollers (7) from bracket (4).
2. Remove four retaining rings (8), two shafts (10), and rollers (9) from bracket (4).
3. Remove two capscrews (2), washers (3), and bracket (4) from bumper (1).
b. Installation
1. Install bracket (4) on bumper (1) with two washers (3) and capscrews (2). Tighten capscrews to
35 lb-ft (47 N•m).
2. Install two rollers (9) and shafts (10) in bracket (4) with four retaining rings (8).
3. Install two rollers (7) and shafts (5) in bracket (4) with four retaining rings (6).
Change 1 10-193
TM 9-2320-280-20-3
1 0 - 1 1 3 . 10,500 LB WINCH HYDRAULIC HOSE REPLACEMENT
This task covers:

INITIAL SETUP:
All vehicles except M996, M996A1, M997, Lubricant (Appendix C, Item 33)
M997A1, M997A2, M1035, M1035A1, Two O-rings (Appendix G, Item 164.1)
M1035A2
Manual References
Tools TM 9-2320-280-10
Equipment Condition
a. Removal
CAUTION
Cover or plug power steering gear and hydro-boost connections
immediately after removing hoses to prevent contamination.
Remove all plugs prior to connecting hoses.
NOTE
Ensure area around power steering port is clean before removing
hose.
1. Remove hydraulic hose (2) and O-ring (5) from power steering gear port (6). Discard O-ring (5).
2. Remove hydraulic hose (2) from winch outlet port (1) on winch (8).
NOTE
Ensure area around hydro-boost port is clean before removing
hose.
3. Remove hydraulic hose (4) and O-ring (5) from hydro-boost port (3). Discard O-ring (5).
4. Remove hydraulic hose (4) from winch inlet port (7).
b. Installation
1. Apply lubricant to O-ring (5) and install O-ring (5) on hydraulic hose (4).
2. Install hydraulic hose (4) on hydro-boost port (3).
3. Route hydraulic hose (4) from hydro-boost port (3) to winch (8) and install hydraulic hose (4) to
winch inlet port (7).
4. Apply lubricant to O-ring (5) and install O-ring (5) on hydraulic hose (2).
5. Install hydraulic hose (2) on power steering gear port (6).
6. Route hydraulic hose (2) from power steering gear port (6) along side hydraulic hose (4) and install
hydraulic hose (2) on winch outlet port (1).
10-194 Change 1
TM 9-2320-280-20-3
1 0 - 1 1 3 . 10,500 LB WINCH HYDRAULIC HOSE REPLACEMENT (Co n t ’ d )
FOLLOW-ON TASK: Bleed power steering system (para. 8-29).
Change 1 10-195/(10-196 blank)

TM 9-2320-280-20-3
CHAPTER 11
SPECIAL PURPOSE BODIES MAINTENANCE
Section I. WEAPON CARRIER BODY MAINTENANCE
11-1. WEAPON CARRIER BODY MAINTENANCE TASK SUMMARY I
I TASK
PARA.
PROCEDURES PAGE
NO.
11-2. Ballistic Crew Door Maintenance 11-5

11-3. Ballistic Crew Door Hinge Replacement 11-8
11-4. Ballistic Crew Door Rear Striker Plate 11-9
Replacement
11-5. Ballistic Crew Door Front Striker Plate 11-10
Maintenance
11-6. Ballistic Crew Door Paddle Lock 11-11
Replacement
11-7. Ballistic Crew Door Window Assembly 11-12
Maintenance
11-8. Ballistic Crew Door Window Protective 11-14
Shield Replacement
11-9. Ballistic Crew Door Window Stop 11-16
Replacement
11-10. Ballistic Crew Door Seal Replacement 11-17
11-11. Ballistic Crew Door Latch Replacement 11-18
11-12. Ballistic Crew Door Latch Tube 11-19
Replacement
11-13. Cargo Shell Door Maintenance 11-20
11-14. Cargo Shell Door Wire Handle Lock 11-26
Replacement
11-15. Cargo Shell Door Grab Handle 11-27
Replacement
11-16. Cargo Shell Door Handle Latch 11-28
Replacement
11-17. Cargo Shell Door Latch Maintenance 11-29
11-18. Cargo Shell Door Latch Rod 11-30
Maintenance
11-19. Cargo Shell Door Dovetail Assembly 11-32
Maintenance
11-20. Cargo Shell Door Retention Cable 11-34
Replacement
11-21. Cargo Shell Door Gas Spring 11-35
Maintenance
11-22. Cargo Shell Door Strap Replacement 11-40
11-23. Cargo Shell Door Seal Protector 11-41
Replacement
11-1
TM 9-2320-280-20-3
1 1 - 1 . WEAPON CARRIER BODY MAINTENANCE TASK SUMMARY (Cont'd)

PARA. NO.
11-24. Cargo Shell Door Seal Replacement 11-42

11-25. Cargo Shell Door Front Striker 11-43
Replacement
11-26. Cargo Shell Door Rear Striker 11-44
Replacement
11-27. Cargo Shell Door Rear Striker Mounting Plate 11-45
Replacement
11-28. Cargo Shell Door Dovetail Spring 11-46
Replacement
11-29. Cargo Shell Door Gas Spring Mounting Bracket 11-47
Replacement
11-30. Cargo Shell Door Liner Replacement 11-48
11-30.1. “B” Pillar Padding Replacement 11-49
11-31. Cargo Shell Roof Insulation Panel 11-50
Replacement
11-32. Hood Side Armor Plate Replacement 11-51
11-33. Hood Center Armor Plate Replacement 11-52
11-34. Hood Top Armored Grille Replacement 11-53
11-35. Hood Front Armored Grille Replacement 11-54
11-36. Right Cowl Armor Plate Replacement 11-55
11-37. Left Cowl Armor Plate Replacement 11-56
11-38. Footwell Armor Plate Replacement 11-57
11-39. Right Wheelhouse Armor Plate Replacement 11-58
11-40. Left Wheelhouse Armor Plate Replacement 11-60
11-41. Tailgate Armor Plate Replacement 11-61
11-42. Weapon Station Hatch Replacement 11-62
11-43. Weapon Station Hatch Handle Replacement 11-63
11-44. Weapon Station Hatch Hinge Pin 11-64
Replacement
11-45. Weapon Station Hatch Hinge Replacement 11-65
11-46. Weapon Station Hatch Holddown Striker 11-67
Replacement
11-47. Weapon Station Tray Seal Replacement 11-68
11-48. Weapon Station Bumper Pad Replacement 11-69
11-49. Weapon Station Tray Lever Replacement 11-70
11-50. Weapon Station Hatch Latch Replacement 11-71
11-51. Weapon Station Hatch Tube Assembly 11-72
Replacement
11-52. Hinge Pivot Bracket and Gunner's Sling 11-73
Replacement
11-53. Gunner's Sling Hook Replacement 11-74
11-54. Weapon Station Backrest Pad Replacement 11-75
11-55. Turret Handle Replacement 11-76
11-2 Change 1
TM 9-2320-280-20-3
11-1. WEAPON CARRIER BODY MAINTENANCE TASK SUMMARY (Cont’d)
I TASK
PARA.
PROCEDURES PAGE
NO.
11-56. Turret Lock Replacement 11-77

11-57. TOW Mount Pedestal Replacement 11-78
11-58. TOW Mount Pedestal Cover Replacement 11-79
11-59. TOW Missile Guidance System Pan Replacement 11-80
11-60. Weapon Station Inclinometer Replacement 11-81
11-61. Armament Mount Panel Replacement 11-82
11-62. Armament Cover and Seal Replacement 11-83
11-63. Gunner’s Platform Replacement 11-84
11-64. Gunner’s Platform Assembly Maintenance 11-86
11-65. Gunner’s Platform Assembly Replacement 11-90
11-66. Vehicle Power Conditioner (VPC) Mounting 11-91
Bracket Replacement
11-67. TOW Wiring Harness Replacement 11-92
11-68. Cable Stowage Cleat Replacement 11-98
11-69. Field Glasses Bracket Replacement 11-99
11-70. Stowage Mount Bracket Replacement 11-100
11-71. Stowage Pedestal Replacement 11-102
11-72. Traversing Unit Mount Adapter 11-103
Maintenance
11-73. Elevation and Depression Stop Assembly 11-104
Maintenance
11-74. M16 Ammo Rack Assembly Replacement 11-106
11-75. TOW Missile Rack Maintenance 11-107
11-76. Water Can Bumper Replacement 11-117
11-77. Missile Guidance Set (MGS) Battery 11-118
Rack Assembly Replacement
11-78. Tripod Leg Mounting Bracket Replacement 11-120
11-79. Tripod Head Mounting Bracket Replacement 11-121
11-80. Fuel Can Tray and Hose Replacement 11-122
11-81. Day Sight Stowage Bracket Replacement 11-123
11-82. Night Sight Support Replacement 11-124
11-83. Night Sight Coolant Base Replacement 11-125
11-84. Front Night Sight Battery Bracket 11-126
Replacement
11-85. Rear Night Sight Battery Bracket 11-127
Replacement
11-86. Boresight Collimator or Night Sight 11-128
Mounting Spacers Replacement
11-3
TM 9-2320-280-20-3
1 1 - 1 . WEAPON CARRIER BODY MAINTENANCE TASK SUMMARY (Cont'd)

PARA. NO.
11-87. Launch Tube Stowage Brackets 11-129

Replacement
11-88. Antenna Blast Shield Replacement 11-130
11-89. Gasoline Cook Stove Bracket Assembly 11-131
Replacement
11-90. Rifle Support Replacement 11-132
11-91. Rifle Mounting Clamp Replacement 11-133
11-92. Rifle Mounting Clamp Bracket Replacement 11-134
11-93. Rifle Mounting Clamp Bracket Replacement 11-135
(M16 A1 Rifle/M203 Grenade Launcher)
11-94. Lower Rifle Mount Bracket Replacement 11-136
11-95. Gun Adapter Plate Assembly Replacement 11-137
11-96. Front Gun Mount Plate Assembly 11-138
Replacement
11-97. Rear Gun Mount Plate Assembly 11-139
Replacement
11-98. Gun Mount Support (Caliber .50) 11-140
Replacement
11-99. Gun Mount Support (40 MM) Replacement 11-141
11-100. Machine Gun Stop Replacement 11-142
11-101. Night Sight Retainer Replacement 11-143
11-102. Tripod Bracket Replacement 11-144
11-103. Double Ammo Box Tray (Caliber .50) 11-145
Replacement
11-104. Ammo Box tray (Caliber .50) Replacement 11-146
11-105. Ammo Box tray (40 MM) and Caliber .50) 11-147
Replacement
11-106 Double Ammo Box Tray (40 MM) 11-148
Replacement
11-107. Triple Ammo Box Tray (40 MM) 11-149
Replacement
11-108. Water Can Tray Replacement 11-150
11-109. Water Can/M13 Decon Can Bumper 11-151
Replacement
11-110. Rear Seat Stowage Compartment Net 11-152
Brackets Replacement
11-111. Cargo Bulkhead Replacement 11-153
11-112. Weapon Station Tray and Bearing 11-154
Seals Maintenance
11-112.1. Turret Cleaning 11-156.2
11-113. Turret Bearing Maintenance 11-158
11-4 Change 1
TM 9-2320-280-20-3
11-2. BALLISTIC CREW DOOR MAINTENANCE

This task covers:
a. Removal c. Inspection
b. Installation d. Adjustment
INITIAL SETUP:
Applicable Models Materials/Parts (Cont’d)
All models except M998, M998A1, M1035, Spacer plate, 0.060-in. (1.5-mm) thick
M1035A1, M1035A2, M1037, M1038, (Appendix G, Item 231)
M1038A1, M1042, M1097, M1097A1, Spacer plate, hinge (Appendix G, Item 232)
M1097A2
Personnel Required
Tools One mechanic
General mechanic’s tool kit One assistant
Manual References
Materials/Parts TM 9-2320-280-24P
Six locknuts (Appendix G, Item 77)
Spacer plate, 0.125-in. (3.2-mm) thick
1. Slide doorstrap (3) off doorstop bracket (2).

2. Open and hold crew door (1) straight out from vehicle. Lift up crew door (1) to remove door hinge
pins (6) from body hinge mounts (5) and remove crew door (1) and washers (4) (if present).
1. Hold crew door (1) straight out from vehicle and insert washers (4) (if removed) and door hinge
pins (6) on body hinge mounts (5).
2. Slide doorstrap (3) on doorstop bracket (2).
11-5
TM 9-2320-280-20-3
11-2. BALLISTIC CREW DOOR MAINTENANCE (Cont’d)
1. Inspect crew door assembly (2) for proper alignment. Ensure door (2) is centered between pillar (7),
roof (5), cargo shell (10), and lower side rail (8). If out-of-alignment condition exists, perform
horizontal or vertical adjustment procedures.
2. Inspect crew door assembly (2) to ensure latch (1) is closing completely on striker (15) without
extreme force. If latch (1) is out of adjustment, perform latch (1) adjustment procedures.
3. Inspect hinge (4) and latch (1) for adjustment. Insert a piece of paper (9) between crew door
assembly (2) and pillar (7), and close door (2). Perform this test at four or five locations around the
door (2). Door seals should offer some resistance when paper is pulled out. If door seal does not offer
resistance, or resistance is excessive, perform hinge and latch adjustment procedures.
4. Inspect latch (1), hinge (4), and door handle (3) for loose, missing, or unserviceable parts.
I d. Adjustment
NOTE
Perform steps 1 and 2 for horizontal adjustment. Perform steps 3
through 6 for vertical adjustment. Perform steps 7 through 18 for
hinge adjustment and steps 19 through 23 for latch adjustment.
1. Loosen six screws (6) from two hinges (4) and crew door assembly (2).
2. Align and center crew door assembly (2) between pillar (7), roof (5), cargo shell (10), and lower side
rail (8). Tighten six screws (6) to 6 lb-ft (8 N-m).
3. Remove door strap (11) from doorstop bracket (12).
4. Open crew door assembly (2) to approximately 45°, and lift and remove door (2) from body hinge
mounts (14).
5. Install washer (13) on each door hinge (4), and install crew door assembly (2) on body hinge
mounts (14).
6. Check vertical adjustment and repeat steps if necessary.
7. Remove door strap (11) from doorstop bracket (12).
8. Open crew door assembly (2) to approximately 45°, and lift door (2) and remove washers (13) (if
installed) from body hinge mounts (14).
9. Remove locknut (19), washer (17), screw (16), washer (17), and doorstop bracket (12) from crew door
assembly (2). Discard locknut (19).
10. Remove five locknuts (20), washers (21), screws (23), washers (21), two hinges (4), and spacer
plates (18) (if installed) from crew door assembly (2). Discard locknuts (20).
11. To increase resistance to that portion of the door seal (22), install two hinge spacer plates (18)
between door hinge (4) and outer side of crew door assembly (2).
12. To decrease resistance to that portion of the door seal (22), discard hinge spacer plate (18) between
door hinge (4) and outer side of crew door assembly (2).
13. Install two spacer plates (18) (if required) and door hinges (4) on crew door assembly (2) with five
washers (21), screws (23), washers (21), and locknuts (20).
14. Install doorstop bracket (12) on crew door assembly (2) with washer (17), screw (16), washer (17),
and locknut (19).
15. Tighten locknuts (19) and (20) installed in steps 13 and 14 to 6 lb-ft (8 Nom).
16. Install two door hinge washers (13) (if removed), position crew assembly door (2) to approximately
45°, and install door hinges (4) on body hinge mounts (14).
17. Check hinge (4) adjustment and repeat steps if necessary.
18. Install door strap (11) on doorstop bracket (12).
11-6
TM 9-2320-280-20-3
11-2. BALLISTIC CREW DOOR MAINTENANCE (Cont’d)
19. Remove crew door latch (para. 11-11).

NOTE
s To increase resistance to door seal and adjust rear of crew door
assembly, perform step 20.
● To decrease resistance to door seal and adjust rear of crew door
assembly, perform step 21.
20. Discard spacer plate(s) (24) from crew door (2).
21. Add spacer plate (24) 0.125-in. (3.2-mm) thick or spacer plate (24) 0.060-in. (1.5-mm) thick to
crew door (2).
22. Install crew door latch (para. 11-11).
23. Check door latch adjustment and repeat steps if necessary.
11-7
TM 9-2320-280-20-3
11-3. BALLISTIC CREW DOOR HINGE REPLACEMENT

This task covers:
INITIAL SETUP:
All models except M998, M998A1, M1035, Three locknuts (Appendix G, Item 77)
M1035A1, M1035A2, M1037, M1038,
M1038A1, M1042, M1097, M1097A1, M1097A2 Manual References
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) Ballistic crew door removed (para. 11-2).
NOTE
● M966, M966A1, M996, M996A1, M997, M997A1, M997A2,
M1025, M1025A1, M1025A2, M1026, M1026A1, and M1036
vehicles have one additional hinge shim on the inner door side of
each door hinge mounting hardware.
● On top hinges, note position of doorstop bracket.
a. Removal
Remove three locknuts (5), washers (2), screws (1), washers (2), hinge (3), and shim(s) (4) from crew
door (6). Discard locknuts (5).
b. Installation
Install shim(s) (4) and hinge (3) on crew door (6) with three washers (2), capscrews (1), washers (2), and
locknuts (5). Tighten locknuts (5) to 6 lb-ft (8 N*m).
FOLLOW-ON TASK: Install ballistic crew door (para. 11-2).
11-8
TM 9-2320-280-20-3
11-4. BALLISTIC CREW DOOR REAR STRIKER PLATE REPLACEMENT I

This task covers:
INITIAL SETUP:
All models except M998, M998A1, M1035, Tape (Appendix C, Item 50)
M1035A1, M1035A2, M1037, M1038, Manual References
M1038A1, M1042, M1097, M1097A1, M1097A2
TM 9-2320-280-24P
Tools
Gereral mechanic’s tool kit:
Remove two capscrews (4), washers (3), and rear striker plate (2) from body (1). Remove tape from rear
striker plate (2) and discard tape.
I b. Installation
Apply tape to rear striker plate (2) mounting surface. Install rear striker plats (2) on body (1) with two
washers (3) and capscrews (4). Tighten capscrews (4) to 8 lb-ft (11 Nom).
11-9
TM 9-2320-280-20-3
11-5. BALLISTIC CREW DOOR FRONT STRIKER PLATE MAINTENANCE

This task covers:
a. Removal c. Adjustment
b. Installation
INITIAL SETUP
All models except M998, M998A1, M1035, Tape (Appendix C, Item 50)
M1035A1, M1035A2, M1037, M1038, Two locknuts (Appendix G, Item 76)
M1038A1, M1042, M1097, M1097A1, M1097A2
Tools TM 9-2320-280-24P
I a. Removal
Remove two locknuts (5), door strap (4), two capscrews (1), and front striker plate (2) from “B” pillar (3).
Discard locknuts (5). Remove tape from front striker plate (2) and discard tape.
Apply tape to front striker plate (2) mounting surface. Install front striker plate (2) on “B” pillar (3) with
two capscrews (1), door strap (4), and two locknuts (5). Finger tighten locknuts (5).
c. Adjustment
1. Close door (6) ensuring latch (7) latches on front striker plate (2).
NOTE
Front striker plates are slotted for vertical adjustment.
2. Press crew door (6) slightly inward and upward until seal (9) contacts body (8). Tighten locknuts (5)
to 19 lb-ft (26 N.m).
3. Open and close crew door (6) several times to ensure proper latch (7) and front striker plate (2)
alignment. If front striker plate (2) cannot be adjusted to align with latch (7), adjust crew door (6)
(para. 11-2).
11-10
TM 9-2320-280-20-3
11-6. BALLISTIC CREW DOOR PADDLE LOCK REPLACEMENT

This task covers:
INITIAL SETUP
Materials/Parts
Applicable Models
All models except M998, M998A1, M1035,
M1038A1, M1042, M1097, M1097A1, M1097A2 TM 9-2320-280-24P
Tools
I a. Removal
1. Release clevis clip (3) from hook (4) and remove hook (4) and clevis clip (3) from paddle lock (2).
2. Remove four locknuts (7), washers (6), screws (5), and paddle lock (2) from crew door (1). Discard
locknuts (7).
1. Install paddle lock (2) on crew door (1) with four screws (5), washers (6), and locknuts (7). Tighten
locknuts (7) to 12-17 lb-in. (1-2 N*m).
2. Connect hook (4) to paddle lock (2) with clevis clip (3).
11-11
TM 9-2320-280-20-3
11-7. BALLISTIC CREW DOOR WINDOW ASSEMBLY MAINTENANCE

This task covers:
INITIAL SETUP:
M1035A1, M1035A2, M1037, M1038,
M1038A1, M1042, M1097, M1097A1, M1097A2 Equipment Condition
● Window stops removed (para. 11-9).
● Latch tube removed (para. 11-12).

Materials/Parts
Retaining ring (Appendix G, Item 174)
Pull out on window latch knob (4) and slide window (5) down and out from door side rails (1) and guide
channel (2).
1. Remove latch knob (4) from pin (6).

2. Remove retaining ring (9), pin (6), and spring (10) from window latch (3). Discard retaining ring (9).
3. Remove four rollers (8) from guide pins (7).
4. Remove four guide pins (7) from window (5).
1. Apply sealing compound to threads of guide pins (7) and install guide pins (7) on window (5) frame.
2. Install spring (10) and pin (6) on window latch (3) with retaining ring (9).
3. Apply sealing compound to threads of pin (6) and install latch knob (4) onto pin (6).
4. Install four rollers (8) on guide pine (7).
Align window latch (3) with window guide channel (2) and push window (5) up into guide channel (2)
and door side rails (1).
11-12
TM 9-2320-280-20-3
11-7. BALLISTIC CREW DOOR WINDOW ASSEMBLY MAINTENANCE Cont’d)
FOLLOW-ON TASKS: ● Install latch tubs (para. 11-12).

● Install window stops (para. 11-9).
11-13
TM 9-2320-280-20-3
11-8. BALLISTIC CREW DOOR WINDOW PROTECTIVE SHIELD REPLACEMENT I

This task covers:
a. Initial Installation c. Installation
b. Removal
INITIAL SETUP:
Applicable Models Materials/Parts (Cont’d)
All models except M998, M998A1, M1035, Two 3/16-in. blind rivets
M1035A1, M1035A2, M1037, M1038, M1038A1, (Appendix G, Item 199)
M1042, M1097, M1097A1, M1097A2
Manual References
Tools TM 43-0139
Materials/Parts
Protective shield (Appendix D, Fig. D-65)
Two 5/32-in. blind rivets (Appendix G, Item 198)
NOTE
. The following procedure can be performed to prevent damage to
door glass. This task can be accomplished with the approval of
the unit commander.
● Procedures for initial installation and replacement of the
protective shields are basically the same for all windows. This
procedure covers the left front protective shield.
I a. Initial Installation
NOTE
Initial installation steps apply only to vehicles that have not been
previously retrofitted with protective shields.
1. Position protective shield (3) on inside of ballistic door (1).
2. Using protective shield (3) as a template, locate and mark three top holes (2) and two bottom
holes (5) on inside of ballistic door (1).
NOTE
Ensure window is closed tightly before drilling holes for the
protective shield.
3. Drill three 0.156-in. (0.396-cm) diameter holes (8) through ballistic door frame (9).
4. Drill two 0.193-in. (0.490-cm) diameter holes (6) through ballistic door (1).
5. Install protective shield (3) on ballistic door fame (9) with three screws (4).
NOTE
Perform step 6 for M966, M966A1, M996, M996A1, M997,
M997A1, M997A2, M1025, M1025A1, M1025A2, M1026, M1026A1,
and M1036 vehicles. Perform step 7 for M1043, M1043A1,
M1043A2, M1044, M1044A1, M1045, M1045A1, M1045A2, M1046,
and M1046A1 vehicles.
6. Install protective shield (3) on ballistic door (1) with two 5/32-in. blind rivets (7).
7. Secure protective shield (3) to ballistic door (1) with two 3/16-in. blind rivets (7).
8. Spot paint ballistic door (1) and protective shield (3) as necessary. Refer to TM 43-0139.
11-14
TM 9-2320-280-20-3
11-8. BALLISTIC CREW DOOR WINDOW PROTECTIVE SHIELD REPLACEMENT (Cont’d)
NOTE
1. Remove two rivets (7) from protective shield (3) and ballistic door 1l).
2. Remove three screws (4) and protective shield (3) from ballistic door frame (9).
1. Install protective shield (3) on ballistic doorframe (9) with three screws (4).
NOTE
Perform step 2 for M966, M966A1, M996, M996A1, M997, M997A1,
M997A2, M1025, M1025A1, M1025A2, M1026, M1026A1, and M1036
vehicles. Perform step 3 for M1043, M1043A1, M1043A2, M1044,
M1044A1, M1045, M1045A1, M1045A2, M1046, and M1046A1
vehicles,
11-15
TM 9-2320-280-20-3
11-9. BALLISTIC CREW DOOR WINDOW STOP REPLACEMENT I

This task covers:
INITIAL SETUP:
M1035A1, M1035A2, M1037, M1038, M1038A1, Manual References
M1042, M1097, M1097A1, M1097A2
TM 9-2320-280-24P
Tools
Gereral mechanic’s tool kit:
CAUTION
If both window stops are being replaced, ensure ballistic window is
locked in the full up position to prevent damage to window.
a. Removal
1. Remove two locknuts (2), screws (5), washers (4), and window stop bracket (6) from side rail (3).
2. Remove locknut (7), washer (8), screw (1), and pad (9) from window stop bracket (6). Discard
locknut (7).
b. Installation
1. Install pad (9) on window stop bracket (6) with screw (1), washer (8), and locknut (7).
2. Install window stop bracket (6) on side rail (3) with two washers (4), screws (5), and locknuts (2).
11-16
TM 9-2320-280-20-3
11-10. BALLISTIC CREW DOOR SEAL REPLACEMENT

This task covers:
a.Removal b. Installation
INITIAL SETUP:
All models except M998, M998A1, M1035, Detergent (Appendix C, Item 17)
M1038A1, M1042, M1097, M1097A1, M1097A2
TM 9-2320-280-24P
Tools
1. Slide door strap (5) off doorstop bracket (4).

2. Start at end of-seal (2) and pry seal (2) from seal retainer (3) around crew door (1).
b. Installation
1. Coat seal (2) with liquid detergent. Start at one end of seal (2) and press seal (2) into retainer (3)
around door (1).
2. Slide door strap (5) on door stop bracket (4).
11-17
TM 9-2320-280-20-3
11-11. BALLISTIC CREW DOOR LATCH REPLACEMENT

This task covers:
INITIAL SETUP:
All models except M998, M998A1, M1035, Capscrew (Appendix G, Item 10)
M1035A1, M1035A2, M1037, M1038, M1038A1, Four locknuts (Appendix G, Item 77)
M1042, M1097, M1097A1, M1097A2 Manual References
Tools TM 9-2320-280-24P
1. Remove clevis clip (6) and hook (7) from paddle lock (10) and disconnect hook (7) from door
latch (14).
2. Disconnect spring (13) from top of latch (14).
3. Remove capscrew (1), wave washer (2), latch tube (3), and washer (4) from latch arm (5). Discard
capscrew (1).
4. Remove four locknuts (15), washer (8), screws (9), latch (14), and spacer (12) from crew door (11)
b. Installation
1. Install spacer (12) and latch (14) on crew door (11) with four washers (8), screws (9), and locknuts (15).
Tighten locknuts (15) to 6 lb-ft (8 N=m).
2. Connect spring (13) to top of latch (14).
3. Install washer (4) and latch tube (3) on latch arm (5) with wave washer (2) and capscrew (1).
Tighten capscrew (1) to 6 lb-ft (8 N~m).
4. Install hook (7) on latch (14) and connect other end of hook (7) to paddle lock (10) with clevis clip (6).
11-18
TM 9-2320-280-20-3
11-12. BALLISTIC CREW DOOR LATCH TUBE REPLACEMENT

This task covers:
INITIAL SETUP:
All models except M998, M998A1, M1035, Capscrew (Appendix G, Item 10)
M1035A1, M1035A2, M1037, M1038, Four screws (Appendix G, Item 209)
M1038A1, M1042, M1097, M1097A1, M1097A2
Tools TM 9-2320-280-24P
I a Removal
1. Remove capscrew (9), wave washer (8), latch tube (7), and washer (3) from latch arm (4). Discard
capscrew (9).
2. Remove four screws (6), washers (5), and bracket (1) from side rails (2). Discard screws (6).
3. Remove two screws (12), washers (13), and guide (11) from bracket (1).
4. Slide latch tube (7) out of bracket (1).
5. Remove protector (10) from bracket (1).
b. Installation
1. Install protector (10) on bracket (1).

2. Slide latch tube (7) into bracket (1).
3. Install guide (11) on bracket (1) with two washers (13) and screws (12).
4. Install bracket (1) on side rails (2) with four washers (5) and screws (6).
5. Install washer (3) and latch tube (7) on latch arm (4) with wave washer (8) and capscrew (9).
Tighten capscrew (9) to 6 lb-ft (8 N.m).
11-19
TM 9-2320-280-20-3
I 11-13. CARGO SHELL DOOR MAINTENANCE

This task covers:
b. Installation
INITIAL SETUP:
All models except M996, M996A1, M997, One mechanic
M997A1, M997A2, M998, M998A1, M1035, One assistant
M1035A1, M1035A2, M1037, M1038,
M1038A1, M1042, M1097, M1097A1, Manual References
M1097A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) Rear end of cargo shell door raised
(TM 9-2320-280-10).
Materials/Parts
Four locknuts (Appendix G, Item 65) General Safety Instructions
Two screw-assembled lockwashers Never open one end of cargo shell door before
(Appendix G, Item 210) ensuring opposite end is securely closed.
WARNING
Opening one end of cargo door before ensuring opposite end is fully
closed will cause both ends to open simultaneously, resulting in
1. Remove two screw-assembled lockwashers (2) and footman loop (3) from strap (1) and cargo
door (4). Discard screw-assembled lockwsahers (2).
2. Lower cargo door (4) slightly, and remove two locknuts (5), washers (6), shoulder bolts (8), and
retention cable (9) from two retention cable brackets (7). Discard locknuts (5).
3. Slowly raise cargo door (4) as far as possible to allow removal of gas springs (10) from cargo door (4).
4. Remove two locknuts (12), washers (11), and gas springs (10) from cargo door (4) and lay gas
springs (10) inside vehicle. Discard locknuts (12).
5. Lower cargo door (4), release handle latch (13), and remove cargo door (4).
11-20
TM 9-2320-280-20-3
11-13.
11-21
TM 9-2320-280-20-3
11-13. CARGO SHELL DOOR MAINTENANCE (Cont’d)
I b. Installation
1. Install front latches (5) on front striker pins (6).

2. Push down on cargo door (4) edge to ensure front striker pins (6) are locked in front latches (5).
3. Slowly raise cargo door (4) as far as possible to allow installation of gas springs (1) on cargo door (4).
4. Connect two gas springs (1) to cargo door (4) with two washers (2) and locknuts (3). Tighten lock-
nuts (3) to 15-20 lb-ft (20-27 N.m).
5. Connect two retention cables (14) to retention cable brackets (12) with two shoulder bolts (13),
washers (11), and locknuts (10). Tighten locknuts (10) to 85-110 lb-in. (10-12 N.m).
6. Install strap (7) on cargo door (4) with footman loop (9) and two screw-assembled lockwashers (8).
NOTE
To assist closing cargo shell door, a grab loop maybe added. Refer to
cargo shell door strap replacement (para. 11-22).
7. Close cargo door (4), and ensure cargo door (4) is securely latched on rear striker pins (15).
11-22
TM 9-2320-280-20-3
11-23
TM 9-2320-280-20-3
I c. Adjustment I
1. Pull rear wire handle (2) and raise rear end of cargo shell door (1).
2. Perform steps 1 through 4 of a., Removal.
3. Close cargo door (1).
4. Release handle latch (3) and push cargo door (1) open.
5. Loosen two front striker pin mounting nuts (5).
6. Loosen two countersunk screws (11) and nuts (10) to allow movement of male dovetail (9).
7. Close cargo door (1). Ensure front striker pins (7) are secured and centered in front latches (6).
8. Ensure male dovetail (9) is aligned with female dovetail (8).
NOTE
It maybe necessary to shim front striker pins for proper door
alignment and operation.
9. Pull down on handle (4) to ensure cargo door (1) properly seals to cargo shell (12). With striker
pins (7) properly adjusted, tighten striker pin mounting nuts (5) to 35-45 lb-ft (47-61 N.m).
10. Release handle latch (3) and push cargo door (1) open.
11. Tighten two nuts (10) on male dovetail (9) to 85-110 lb-in. (10-12 N.m).
12. Lower cargo door (1). Ensure front striker pins (7) are secured and centered in front latches (6).
13. Raise cargo door (1) from rear wire handle (2) and perform steps 3 through 6 of b., Installation.
14. Insert a piece of paper between door seals and door opening. With cargo door closed, seals should
offer resistance when pulling out paper. If door seals do not offer resistance, readjust cargo door.
11-24
TM 9-2320-280-20-3
FOLLOW-ON TASK: Close cargo shell door (TM 9-2320-280-10).
11-25
TM 9-2320-280-20-3
11-14. CARGO SHELL DOOR WIRE HANDLE LOCK REPLACEMENT

This task covers:
INITIAL SETUP:
All models except M996, M996A1, M997, M997A1, Sealing compound (Appendix C, Item 45)
M997A2, M998, M998A1, M1035, M1035A1, Two pushnuts (Appendix G, Item 169)
M1035A2, M1037, M1036, M1038A1, M1042,
M1097, M1097A1 M1097A2 Manual References
TM 9-2320-280-10
Tools TM 9-2320-280-24P
Tailgate lowered (TM 9-2320-280-10).
a. Removal
1. Remove two pushnuts (1), rod end clips (2), and latch rods (3) from wire handle lock pivot
arms (4). Discard pushnuts (1).
2. Remove four nuts (5), washers (6), capscrews (8), washers (6), and wire handle lock (9) from cargo
door (7).
I b. Installation
I
1. Apply sealing compound to threads of capscrews (8).
2. Install wire handle lock (9) on cargo door (7) with four washers (6), capscrews (8), washers (6), and
nuts (5).
3. Install two latch rods (3) on wire handle lock pivot arms (4) with rod end clips (2) and pushnuts (1).
FOLLOW-ON TASKS: c Raise and secure tailgate (TM 9-2320-280-10).

● Check cargo shell door for proper operation (TM 9-2320-280-10).
11-26
TM 9-2320-280-20-3
11-15. CARGO SHELL DOOR GRAB HANDLE REPLACEMENT

I
This task covers:
INITIAL SETUP:
Applicable Models
Materials/Parts
M997A1, M997A2, M998, M996A1, M1035, Sealing compound (Appendix C, Item 45)
M1035A1, M1035A2, M1037, M1038, Four lockwashers (Appendix G, Item 120)
Tools TM 9-2320-280-10
Forward end of cargo shell door raised
(TM 9-2320-280-10).
a. Removal
Remove four nuts (1), lockwashers (2), washers (3), countersunk screws (6), and grab handle (5) from
cargo door (4). Discard lockwashers (3).
I b. Installation
1. Apply sealing compound to threads of countersunk screw (6).
2. Install grab handle (5) on cargo door (4) with four countersunk screws (6), washers (3),
11-27
TM 9-2320-280-20-3
11-16. CARGO SHELL DOOR HANDLE LATCH REPLACEMENT

This task covers:
INITIAL SETUP
All models except M996, M996A1, M997, Two pushnuts (Appendix G, Item 169)
M997A1, M997A2, M998, M998A1, M1035,
M1038A1, M1042, M1097, M1097A1, M1097A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) Forward end of cargo shell door raised
(TM 9-2320-280-10).
a. Removal
1. Remove four nuts (4), washers (3), capscrews (5), and washers (3) from handle latch lock (1) and
cargo door (2).
2. Pull handle latch (1) out and down until latch rods (6) are visible.
3. Remove two pushnuts (9), rod end clips (7), latch rods (6), and handle latch (1) from pivot arms (8).
Discard pushnuts (9).
1. Position handle latch (1) to cargo door (2) until latch rods (6) can be connected to handle latch pivot
arms (8) and secure latch rods (6) on pivot arms (8) with two rod end clips (7) and push-nut-s (9).
2. Install handle latch (1) on cargo door (2) with four washers (3), capscrews (5), washers (3), and
nuts (4).
FOLLOW-ON TASK: Check cargo shell door for proper operation (TM 9-2320-280-10).
11-28
TM 9-2320-280-20-3
11-17. CARGO SHELL DOOR LATCH MAINTENANCE

This task covers:
b. Installation
INITIAL SETUP
All models except M996, M996A1, M997, Three lockwashers (Appendix G, Item 109)
M997A1, M997A2, M998, M998A1, M1035, Pushnut (Appendix G, Item 169)
M1035A1, M1035A2, M1037, M1038,
TM 9-2320-280-10
Tools TM 9-2320-280-24P
Rear end of cargo shell door raised
(TM 9-2320-280-10).
1. Remove pushnut (6), rod end clip (7), and rod (8) from door latch (4). Discard pushnut (6).
2. Remove three nuts (1), lockwashers (2), capscrews (5), and door latch (4) from cargo door (3). Discard
lockwashers (2).
I b. Installation
Install door latch (4) on cargo door (3) with three capscrews (5), lockwashers (2), and nuts (1). DO not
tighten nuts (1) all the way.
I c. Adjustment I
1. Loosen three nuts (1) from door latch (4) and cargo door (3).
2. Close cargo door (3) ensuring latch (4) is fully engaged on door striker pins (9).
3. Tighten three nuts (1) to 17 lb-ft (23 Nom).
4. Install rod (8) on latch (4) with rod end clip (7) and pushnut (6).
FOLLOW-ON TASKS: ● Lubricate door latch (TM 9-2320-280-10).

● Check cargo shell door for proper operation (TM 9-2320-280-10).
11-29
TM 9-2320-280-20-3
11-18. CARGO SHELL DOOR LATCH ROD MAINTENANCE

This task covers:
b. Installation
INITIAL SETUP:
All models except M996, M996A1, M997, Two pushnuts (Appendix G, Item 169)
M997A1, M997A2, M998, M998A1, M1035,
M1035A1, M1035A2, M1037, M1038, M1038A1,
M1042, M1097, M1097A1, M1097A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
(TM 9-2320-280-10).
NOTE
Maintenance procedures for all cargo shell door latch rods are
basically the same. This procedure covers the left rear latch rod.
1. Remove pushnut (1), rod end clip (3), and latch rod (4) from pivot arm (2) on wire handle
lock (5). Discard pushnut (1).
2. Remove pushnut (7), rod end clip (6), and latch rod (4) from door latch (8). Discard pushnut (7).
1. Connect latch rod (4) to door latch (8) with rod end clip (6).
2. Connect latch rod (4) to pivot arm (2) on wire handle lock (5) with rod end clip (3) and pushnut (1).
3. Close forward end of cargo door.
I c. Adjustment
1. Open rear end of cargo door.

2. Close both rear door latches (8) to check latch action.
3. Gently pull wire handle lock (5) and observe movement of door latches (8). If both door latches (8)
unlatch at the same time, install pushnut (7) on latch rod (4), no adjustment is necessary. If door
latches (8) do not unlatch at the same time, go to step 4.
4. Remove rod end clip (6) from rod (4) and door latch (8). Rotate rod adjuster (9) in, if door latch (8)
unlatches after opposite latch (8), or rotate rod adjuster (9) out, if door latch (8) unlatches before
opposite door latch (8).
5. Repeat step 4 until door latches (8) unlatch at the same time.
6. Install latch rod (4) on door latch (8) with rod end clip (6) and pushnut (7).
11-30
TM 9-2320-280-20-3
11-18. CARGO SHELL DOOR LATCH ROD MAINTENANCE (Cont’d)
11-31
TM 9-2320-280-20-3
11-19. CARGO SHELL DOOR DOVETAIL ASSEMBLY MAINTENANCE

This task covers:
b. Installation
INITIAL SETUP:
Materials/Parts
Applicable Models
All models except M996, M996A1, M997, Two lockwashers (Appendix G, Item 124)
M997A1, M997A2, M998. M998A1. M1035.
M1035A1, M1035A2, M1037, M 1038, Manual References
M1038A1, M1042, M1097, M1097A1, M1097A2 TM 9-2320-280-24P
General mechanic’s tool kit: Rear end of cargo shell door raised
NOTE
The cargo shell door dovetail assembly is of two-piece construction.
The female half is mounted on the cargo door. The male half is
mounted on a bracket attached to the left cargo shell. Both halves
are adjustable and function as a door alignment device.
a. Removal
1. Remove two capscrews (1), lockwashers (2), washers (3), and female dovetail (4) from cargo door (5).
2. Remove two locknuts (6), washers (7), countersunk screws (11), male dovetail (10), and shim (9) from
cargo shell bracket (8). Discard locknuts (6).
1. Install shim (9) and male dovetail (10) on cargo shell bracket (8) with two countersunk screws (11),
washers (7), and locknuts (6). Leave male dovetail (10) loose enough to allow movement from left to
right.
2. Install female dovetail (4) on cargo door (5) with two washers (3), lockwashers (2), and capscrews (1).
Leave dovetail (4) loose enough to allow movement up and down.
3. Close rear end of cargo door (5).
1. Open forward end of cargo door (5).

2. Loosen two capscrews (1) from female dovetail (4) and cargo door (5) until female dovetail (4) will
slide up and down.
3. Loosen two countersunk screws (11) and locknuts (6) from male dovetail (10) and cargo shell
bracket (8) until male dovetail (10) can be moved from left to right.
4. Gently close cargo door (5) until male dovetail (10) and female dovetail (4) folly seat without
interference. Once this condition exists, tighten mounting hardware of dovetails (4) and (10).
5. Open and close cargo door (5) several times to ensure proper dovetail (4) and (10) adjustment.
6. Tighten two capscrews (1) on female dovetail (4) to 10 lb-ft (14 N-m).
7. Tighten two locknuts (6) on male dovetail (10) to 85-100 lb-in. (10-11 N.m).
11-32
TM 9-2320-280-20-3
11-19. CARGO SHELL DOOR DOVETAlL ASSEMBLY MAINTENANCE (Cont’d)
11-33
TM 9-2320-280-20-3
11-20. CARGO SHELL DOOR RETENTION CABLE REPLACEMENT

This task covers:
INITIAL SETUP:
All models except M996, M996A1, M997, Two locknuts (Appendix G, Item 65)
M997A1, M997A2, M998, M998A1, M1035, Manual References
M1035A1, M1035A2, M1037, M1038, M1038A1, TM 9-2320-280-10
M1042, M1097, M1097A1, M1097A2 TM 9-2320-280-24P
General mechanic’s tool kit: F’orward end of cargo shell door raised
NOTE
It will be necessary to lower cargo shell door slightly to relieve
cable tension during step 1.
1. Remove locknut (1), washer (2), shoulder bolt (4), and spring end of cable (5) from cargo door
2. Remove locknut (8), washer (9), shoulder bolt (6), and cable (5) from left cargo shell bracket (7).
I b. Installation I
1. Install cable (5) on cargo shell bracket (7) with shoulder bolt (6), washer (9), and locknut (8).
Tighten locknut (8) to 85-110 lb-in. (10-12 N-m).
2. Install spring end of cable (5) on cargo door bracket (3) with shoulder bolt (4), washer (2), and
and locknut (1). Tighten locknut (1) to 85-110 lb-in. (10-12 Nom).
11-34
TM 9-2320-280-20-3
11-21. CARGO SHELL DOOR GAS SPRING MAINTENANCE

This task covers:
a. Rotating d. Assembly
b. Removal e. Installation
c. Disassemble
INITIAL SETUP:
Applicable Models
One mechanic
All models except M996, M996A1, M997, One assistant
M997A1, M997A2, M998, M998A1, M1035,
M1038A1, M1042, M1097, M1097A1, M1097A2
TM 9-2320-280-10
Tools TM 9-2320-280-24P
Materials/Parts (TM 9-2320-280-10).
Grease (Appendix C, Item 22) General Safety Instructions
Two retaining rings (Appendix G, Item 175) s Do not attempt to remove gas cylinders from
Two screw-assembled lockwashers Spring rods.
● One assistant will be required to hold the cargo
door open when either one or both gas springs
are being removed or installed.
NOTE
“ Prior to starting any maintenance, ensure forward end of cargo
shell door is locked.
“ A 2 x 4 x 79.25 inch long board can used to support cargo door
in the open position.
1. Remove cargo shell door strap (para. 11-22).
2. Remove cargo shell door retention cable (para. 11-20).
3. Secure rear cargo door (1) in full open position.
11-35
TM 9-2320-280-20-3
11-21. CARGO SHELL DOOR GAS SPRING MAINTENANCE (Cont’d)

4. Remove four retaining rings (1) from rod sockets (2) on two gas spring assemblies (5).
WARNING
Do not attempt to remove gas spring assemblies from ball stubs
until cargo door is supported in full open position. Failure to do so
may result in injury to personnel or damage to equipment.
5. Remove left and right gas spring assemblies (5) from ball studs (3) on cargo door (4) and body
bracket (6).
6. Invert left gas spring assembly (5) 180 degrees and position to right side of vehicle.
7. Invert right gas spring assembly (5) 180 degrees and position to left aide of vehicle.
8. Install left and right gas spring assemblies (5) over ball studs (3) on cargo door (4) and body
brackets (6).
9. Install four retaining rings (1) in rod sockets (2) on two gas springs (5).
10. Remove cargo door support.
11. Install cargo shell retention cable (para. 11-20).
12. Install cargo shell door strap (pars.. 11-22).
13. Check operation of cargo shell door (TM 9-2320-280-10).
11-36
TM 9-2320-280-20-3
WARNING
One assistant will be required to hold the cargo door open when
either one or both gas springs are being removed or installed.
Failure to do so may result in injury to personnel or damage to
equipment.
I b. Removal I
1. Remove two locknuts (1), washers (2), shoulder bolts (4), and retention cables (5) from cargo door (3).
2. Remove two screw-assembled lockwashers (6), footman loop (7), and cargo door strap (8) from cargo
door (3). Discard screw-assembled lockwashers (6).
11-37
TM 9-2320-280-20-3
3. Remove two locknuts (1), washers (2), and gas spring assembly (4) from cargo door (3) and body
bracket (5). Discard locknuts (1).
1. Remove inner spring tube (6) from outer spring tube (13).
2. Remove two retaining rings (8) from ball studs (11) and rod sockets (12). Remove two ball
studs (11) from rod sockets (12). Discard retaining rings (8).
3. Remove two clamps (10) from bushings (9) and spring rods (7) and (14). Pull spring rods (7)
and (14) out of tubes (6) and (13) 1-inch (2.54 cm), and remove two bushings (9).
WARNING
Do not attempt to remove gas cylinders from inner spring rod or
outer spring rod. High internal pressure will cause cylinder to
explode, resulting in injury to personnel.
4. Pull inner spring rod (7) from inner tube (6) and outer spring rod (14) nom outer tube (13).
1. Install longer outer spring rod (14) on outer tube (13), leaving about 1-inch (2.54 cm) of the small
diameter portion of the rod (14) exposed to install bushing (9).
2. Install bushing (9) on outer spring rod (14). Ensure bushing (9) is fully seated on outer
tube (13) and rod socket (12) end is fully seated on bushing (9). Install and tighten clamp (10).
3. Place grease in rod end socket (12), and install ball stud (11) on socket (12) with retaining ring (8).
4. Repeat steps 1-3 for inner tube (6) and inner spring rod (7).
5. Install inner tube (6) into outer tube (13).
e. Installation
1. Install gas spring (4) on body bracket (5) and cargo door (3) with two washers (2) and locknuts (1).
Tighten locknuts (1) to 15-20 lb-ft (20-27 N.m).
2. Install footman loop (16) and cargo door strap (17) on cargo door (3) with two screw-assembled
lockwashers (15).
3. Install two retention cables (21) on cargo door (3) with two shoulder bolts (20), washers (19), and
locknuts (18). Tighten locknuts (18) to 85-110 lb-in. (10-12 Nom).
11-38
TM 9-2320-280-20-3
11-39
TM 9-2320-280-20-3
11-22. CARGO SHELL DOOR STRAP REPLACEMENT

This task covers:
INITIAL SETUP:
.
All models except M996, M996A1, M997, Locknut (Appendix G, Item 65)
M997A1, M997A2, M998, M998A1, M1035, Two screw-assembled lockwashers
M1038A1, M1042, M1097, M1097A1, M1097A2
Manual References
Tools TM 9-2320-280-10
Equipment Condition
(TM 9-2320-280-10).
a. Removal
1. Remove two screw-assembled lockwashers (3), footman loop (2), and strap (1) from cargo door (4).
Discard screw-assembled lockwashers (3).
2. Remove locknut (5), washer (6), capscrew (7), and strap (1) from left striker mounting plate (8).
b. Installation
NOTE
To assist closing cargo shell door, a grab loop maybe added. Refer
to appendix D, figure D-83.
1. Install strap (1) on left striker mounting plate (8) with capscrew (7), washer (6), and locknut (5).
Tighten locknut (5) to 25-30 lb-ft (34-41 N.m).
2. Install strap (1) and footman loop (2) on cargo door (4) with two screw-assembled lockwashers (3).
11-40
TM 9-2320-280-20-3
11-23. CARGO SHELL DOOR SEAL PROTECTOR REPLACEMENT

This task covers:
lNITIAL SETUP:
All models except M996, M996A1, M997, Thirteen locknuts (Appendix G, Item 65 )
M997A1, M997A2, M998, M998A1, M1035,
M1038A1, M1042, M1097, M1097A1, M1097A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
General mechanic’s tool kit Equipment Condition
automotive (Appendix B, Item 1) Rear end of cargo shell door raised
(TM 9-2320-280-10).
Remove thirteen locknuts (4), washers (5), capscrews (2), washers (5), and seal protector (1) from cargo
Install seal protector (1) on cargo door (3) with thirteen washers (5), capscrews (2), washers (5), and
locknuts (4). Tighten locknuts (4) to 85-100 lb-in. (10-12 N-m).
11-41
TM 9-2320-280-20-3
I 11-24. CARGO SHELL DOOR SEAL REPLACEMENT

This task covers:
lNITIAL SETUP:
Applicable Models .
Materals/Parts
All models except M998, M998A1, M997, Sealing compound (Appendix C, Item 40)
M997A1, M997A2, M998, M998A1, M1035,
M1038A1, M1042, M1097, M1097A1, TM 9-2320-280-24P
M1097A2
Equipment Condition
Tools Cargo shell door seal protector removed
Remove seal (1) from cargo door (2). Clean edge around cargo door (2) to remove dirt, corrosion, or
remaining adhesive.
I b. Installation
1. Install seal (1) on cargo door (2), making sure seal (1) is fully seated.
2. Detach seal (1) at rear edge of cargo door (2) only, and apply sealing compound in seal (1) channel
the entire length of rear edge of cargo door (2).
3. Install seal (1) on rear edge of cargo door (2), making sure seal (1) is fully seated.
FOLLOW-ON TASK: Install cargo shell door seal protector (para. 11-23).
11-42
TM 9-2320-280-20-3
11-25. CARGO SHELL DOOR FRONT STRIKER REPLACEMENT

This task covers:
INITIAL SETUP:
M997A1, M997A2, M998, M998A1, M1035,
M1038A1, M1042, M1097, M1097A1, M1097A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
(TM 9-2320-280-10).
a. Removal
Remove locknut (4), washer (2), front striker (3), and washer (2) from body bracket (1). Discard locknut (4).
Install washer (2) and front striker (3) on body bracket (1) with washer (2) and locknut (4). Tighten
locknut (4) to 35-45 lb-ft (47-61 N.m).
FOLLOW-ON TASK: Adjust cargo shell door (para. 11-13).
11-43
TM 9-2320-280-20-3
I 11-26. CARGO SHELL DOOR REAR STRIKER REPLACEMENT I

This task covers:
INITIAL SETUP:
Applicable Models
M1035A1, M1035A2, M1037, M1038,
TM 9-2320-280-10
Tools TM 9-2320-280-24P
. Tailgate lowered (TM 9-2320-280-10).
Materials/Parts ● Rear end of cargo shell door raised
Locknut (Appendix G, Item 79) (TM 9-2320-280-10).
Remove locknut (4), washer (3), striker (1), and spacer (2) from striker plate (6) and wheelhouse (5).
I b. Installation
Install spacer (2) and striker (1) on striker plate (6) and wheelhouse (5) with washer (3) and locknut (4).
Tighten locknut (4) to 190-210 lb-ft (258-285 N.m).
FOLLOW-ON TASKS: ● Raise and secure tailgate (TM 9-2320-280-10).

● Close cargo shell door (TM 9-2320-280- 10).
11-44
TM 9-2320-280-20-3
11-27. CARGO SHELL DOOR REAR STRIKER MOUNTING PLATE REPLACEMENT

This task covers:
INITIAL SETUP:
M997A1, M997A2 M998, M998A1, M1035, One assistant
M1035A1, M1035A2, M1037, M1038,
M1097A2 TM 9-2320-280-10
TM 8-2320-280-24P
Tools
automotive (Appendix B, Item 1) ● Rear striker removed (para. 11-26).
● Cargo shell door strap removed (left side only)
1. Remove locknut (5), washer (4), and socket head screw (2) from striker mounting plate (3) and
wheelhouse (8). Discard locknut (5).
2. Remove five locknuts (6), washers (7), capscrews (1), washers (9), and striker mounting plate (3)
from wheelhouse (8). Discard locknuts (6).
I b. Installation
1. Install striker mounting plate (3) on wheelhouse (8) with five washers (9), capscrews (1), washers (7),
and locknut.s (6).
2. Secure striker mounting plate (3) to wheelhouse (8) with socket head screw (2), washer(4), and
locknut (5). Tighten locknuts (5) and (6) to 25-30 lb-ft (34-41 N.m).
FOLLOW-ON TASKS: ● Install cargo shell door strap (left side only) (para. 11-22).
● Install rear striker (para. 11-26).
11-45
TM 9-2320-280-20-3
11-28. CARGO SHELL DOOR DOVETAIL SPRING REPLACEMENT I

This task covers:
INITIAL SETUP:
M997A1, M997A2, M998, M998A1, M1035, TM 9-2320-280-24P
M1035A1, M1035A2, M1037, M1038,
M1036A1, M1042, M1097, M1097A1, M1097A2 Equipment Condition
l Rear end of cargo shell door raised
Tools (TM 9-2320-280-10).
General mechanic’s tool kit: . Tailgate lowered (TM 9-2320-280-10).
Materials/Parts
I a. Removal
Remove locknut (8), lockwasher (7), washer (6), cup (9), spring (3), locknut (2), retainer (10), and head
bolt (1) from cargo shell dovetail (5). Discard locknuts (2) and (8) and lockwasher (7).
1. Install retainer (10) and locknut (2) on head bolt (1) and position locknut (2) to end of threads on
head bolt (1).
2. Install cup (9) and head bolt (1) on dovetail (5).
3. Lower cargo door.
4. Hold locknut (2) and adjust head bolt (1) up until head bolt (1) touches bottom of cargo door (4).
5. Raise cargo door.
6. Remove head bolt (1) from dovetail (5).
7. Install spring (3), cup (9), and head bolt (1) on dovetail (5) with washer (6), lockwasher (7), and
locknut (8). Tighten locknut (8) to 55 lb-ft (75 N.m).
FOLLOW-ON TASKS: l Close cargo shell door (TM 9-2320-280-10).

l Raise and secure tailgate (TM 9-2320-280-10).
11-46
TM 9-2320-280-20-3
11-29. CARGO SHELL DOOR GAS SPRING MOUNTING BRACKET REPLACEMENT

This task covers:
INITIAL SETUP:
M997A1, M997A2, M998 M998A1, M1035, One assistant
M1035A1, M1035A2, M1037, M1038,
TM 9-2320-280-10
Tools TM 9-2320-280-24P
l Tailgate lowered (TM 9-2320-280-10).
Materials/Parts . Gas spring removed (para. 11-21).
Tape (Appendix C, Item 50)
I a. Removal
1. Remove two locknuts (9), washers (1), capscrews (2), and washers (1) from bracket (3) and
wheelhouse (6). Discard locknuts (9).
2. Remove two locknuts (8), washers (4), backing plate (7), capscrews (5), washers (4), and bracket (3)
from wheelhouse (6). Discard locknuts (8). Remove tape from bracket (3) and discard tape.
b. Installation
1. Apply tape to bracket (3) mounting surfaces. Install bracket (3) on wheelhouse (6) with two
washers (4), capscrews (5), backing plate (7), washers (4), and locknuts (8). Tighten locknuts (8) to
8 lb-ft (11 N=m~.
2. Secure bracket (3) to wheelhouse (6) with two washers (1), capscrews (2), washers (1), and
locknuts (9). Tighten locknuts (9) to 8 lb-ft (11 N-m).
FOLLOW-ON TASKS: “ Install gas spring (para. 11-21).

. Raise and secure tailgate (TM 9-232-280-10).
11-47
TM 9-2320-280-20-3
I 11-30. CARGO SHELL DOOR LINER REPLACEMENT

This task covers:
INITIAL SETUP
M966, M966A1, M1025, M1025A1, M1025A2, One mechanic
M1026, M1026A1, M1036 One assistant
Twelve clips (Appendix G, Item 14) Rear end of cargo shell door raised
(TM 9-2320-280-10).
1. Remove ten screws (6), washers (5), clips (4), and two retainers (7) from cargo shell door (1).
2. Remove twelve fastener clips (8) from liner (3) and door (1). Discard fastener clips (8).
3. Remove liner (3) and three sound dampeners (2) from door (1).
4. Clean cargo door (1) to remove adhesive.
NOTE
Ensure surface is free of dirt and oil before applying adhesive
backing.
1. Apply three sound dampeners (2) to door (1).
2. Place four fastener clips (8) in two top and two bottom holes of liner (3). Ensure heads of fastener
clips (8) are on side of liner (3) without adhesive.
3. Peel paper backing (9) from liner (3).
4. Align liner (3) with door (1), ensuring top and bottom fastener clips (8) in liner (3) align with top and
bottom holes in door (1), and install liner (3) on door (1) with top and bottom fastener clips (8). Press
entire surface of liner (3) to ensure adhesion.
5. Install eight remaining fastener clips (8) through liner (3) into door (1).
6. Install two retainers (7) on door (1) with ten clips (4), washers (5), and screws (6).
11-48
TM 9-2320-280-20-3
1 1 - 3 0 . CARGO SHELL DOOR LINER REPLACEMENT(Cont'd)
Change 1 11-48.1/(11-48.2 blank)

TM 9-2320-280-20-3
1 1 - 3 0 . 1 . “B” PILLAR PADDING REPLACEMENT

This task covers:
INITIAL SETUP:
M966, M1025, M1026, M1036, M1043, TM 9-2320-280-24P
M1044, M1045, M1046, M1121
Equipment Condition
Materials/Parts Remove rifle mounting clamp bracket (if equipped)
Two locknuts (Appendix G, Item 106) (para. 11-92).
a. Removal
1. Remove locknut (8), washer (7), capscrew (6), and washer (7) from padding (3) and “B” pillar (11).
2. Remove locknut (10), washer (4), capscrew (5), and washer (4) from padding (3) and “B” pillar (11).
3. Remove screw (1), washer (2), and padding (3) from“B” pillar (11).
4. Remove edge trim (9) from “B” pillar (11).
b. Installation
1. Install edge trim (9) on “B” pillar (11).
2. Install padding (3) on “B” pillar (11) with washer (2) and screw (1).
3. Secure padding (3) to “B” pillar (11) with washer (4), capscrew (5), washer (4), and locknut (10).
4. Secure padding (3) to “B” pillar (11) with washer (7), capscrew (6), washer (7), and locknut (8).
FOLLOW-ON TASK: Install rifle mounting clamp bracket (if removed) (para. 11-92).
Change 1 11-49
TM 9-2320-280-20-3
1 1 - 3 1 . CARGO SHELL ROOF INSULATION PANEL REPLACEMENT
This task covers:

INITIAL SETUP:
M966, M966A1, M1025, M1025A1, Primer adhesive (Appendix C, Item 35)
M1025A2, M1026, M1026A1, M1036,
M1121 Manual References
TM 9-2320-280-24P
Tools
a. Removal
1. Remove insulation panel (2) from roof (1).

2. Clean roof (1) surface to remove adhesive.
b. Installation
1. Spray primer adhesive on roof (1), peel paper backing (3) from panel (2), and install panel (2)
on roof (1).
2. Press panel (2) surface to ensure adhesion.
11-50 Change 1
TM 9-2320-280-20-3
11-32. HOOD SIDE ARMOR PLATE REPLACEMENT

This task covers:
INITIAL SETUP:
M1035A1, M1035A2, M1037, M1038, TM 9-2320-280-24P
M1038A1, M1042, M1097, M1097A1, M1097A2
Equipment Condition
Tools Hood raised and secured (TM 9-2320-280-10).
Remove four capscrews (4), washers (5), and armor plate (1) from hood (2).
b. Installation
Slide narrow end of armor plate (1) between radiator-to-hood seal (3) and hood (2) until holes align, and
install on hood (2) with four washers (5) and capscrews (4). Tighten capscrews (4) to
15-20 lb-in. (2 N.m).
11-51
TM 9-2320-280-20-3
11-33. HOOD CENTER ARMOR PLATE REPLACEMENT

This task covers:
INITIAL SETUP:
M1035A1, M1035A2, M1037, M1038, TM 9-2320-280-24P
M1038A1, M1042, M1097, M1097A1, M1097A2
Equipment Condition
a. Removal
Remove nine capscrews (5), washers (6), hood seal retainer (4), hood-to-radiator seal (3), and armor
plate (2) from hood (1).
I b. Installation
Install armor plate (2), hood-to-radiator seal (3), and hood seal retainer (4) on hood (1) with nine
washers (6) and capscrews (5). Tighten capscrews (5) to 15-20 lb-in. (2 N.m).
11-52
TM 9-2320-280-20-3
11-34. HOOD TOP ARMORED GRILLE REPLACEMENT

This task covers:
INITIAL SETUP:
M1035A1, M1035A2, M1037, M1038, M1038A1, One assistant
M1042, M1097, M1097A1, M1097A2
Manual References
Tools TM 9-2320-280-10
Equipment Condition
Materials/Parts Hood raised and secured (TM 9-2320-280-10).
Remove four locknuts (5), washers (2), capscrews (3), washers (2), and top grille (1) from hood (4).
Install grille (1) on hood (4) with four washers (2), capscrews (3), washers (2), and locknuts (5).
Tighten locknuts (5) to 6 lb-ft (8 N-m).
11-53
TM 9-2320-280-20-3
11-35. HOOD FRONT ARMORED GRILLE REPLACEMENT

This task covers:
INITIAL SETUP:
M1035A1, M1035A2, M1037, M1038, M1038A1, Three lockwashers (Appendix G, Item 109)
M1042, M1097, M1097A1, M1097A2
Manual References
TOOlS TM 9-2320-280-10
automotive ( Appendix B, Item 1)
Equipment Condition
1. Remove three locknuts (5), washers (4), and carriage bolts (2) from front grille (3) and hood (1).
2. Remove three capscrews (6), harness clamps (7), lockwashers (8), washers (9), and grille (3) from
hood (1). Discard lockwashers (8).
1. Install front grille (3) on hood (1) with three washers (9), lockwashers (8), harness clamps (7), and
capscrews (6).
2. Secure grille (3) to hood (1) with three carriage bolts (2), washers (4), and locknuts (5).
3. Tighten locknuts (5) to 21 lb-ft (29 N.m). Tighten capscrews (6) to 20-30 lb-in. (2-3 N.m).
11-54
TM 9-2320-280-20-3
11-36. RIGHT COWL ARMOR PLATE REPLACEMENT

This task covers:
INITIAL SETUP:
Applicable Models
All models except M988, M998A1, M1035, Four locknuts (Appendix G, Item 65)
M1035A1, M1035A2, M1037, M1038,
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) Ballistic crew door removed (para. 11-2).
Remove four locknuts (2), washers (1), screws (5), washers (4), and armor plate (6) from cowl (3).
Install armor plate (6) on cowl (3) with four washers (4), screws (5), washers (1), and locknuts (2).
11-55
TM 9-2320-280-20-3
11-37. LEFT COWL ARMOR PLATE REPLACEMENT

This task covers:
lNITIAL SETUP:
All models except M998, M998A1, M1035, Seven locknuts (Appendix G, Item 65)
M1035A1, M1035A2, M1037, M1038,
M1097A2 TM 9-2320-280-24P
General mechanic’s tool kit: Ballistic crew door removed (para. 11-2).
Remove seven locknuts (1), washers (2), screws (4), washers (5), and armor plate (3) from cowl (6)
b. Installation
Install armor plate (3) on cowl (6) with seven washers (5), screws (4), washers (2), and locknuts (1).
11-56
TM 9-2320-280-20-3
11-38. FOOTWELL ARMOR PLATE REPLACEMENT

This task covers:
INITIAL SETUP:
M1035A1, M1035A2, M1037, M1038,
M1097A2 TM 9-2320-280-24P
Tools
Remove four locknuts (3), washers (2), screws (6), washers (5), armor plate (1), and four spacers (7) from
b. Installation
Install four spacers (7) and armor plate (1) on body (4) with four washers (5), screws (6), washers (2),
and locknuts (3). Tighten locknuts (3) to 6 lb-ft (8 N-m).
11-57
TM 9-2320-280-20-3
I 11-39. RIGHT WHEELHOUSE ARMOR PLATE REPLACEMENT

This task covers:
INITIAL SETUP:
M1025, M1025A1, M1025A2, M1026, One mechanic
M1026A1, M1043, M1043A1, M1043A2, One assistant
M1044, M1044A1, M1045, M1045A1,
M1045A2, M1046, M1046A1 Manual References
TM 9-2320-280-10
Tools TM 9-2320-280-24P
l Rear end of cargo shell door raised
Materials/Parts (TM 9-2320-280-10).
Fourteen locknuts (Appendix G, Item 58) M1045, M1045A1, M1045A2, M1046, and M1046A1
Sound dampener (Appendix G, Item 228) only
l Night sight support assembly removed (para. 11-82).
M1043, M1043A1, M1043A2, M1044, and M1044A1
only
l Machine gun stop removed (para. 11-100).
a. Removal
1. Remove four locknuts (7), washers (6), screws (9), and two footman loops (8) from wheelhouse (3).
2. Remove ten locknuts (5), washers (4), capscrews (10), washers (4), armor plate (1), and sound
dampener (2) from wheelhouse (3). Discard locknuts (5) and sound dampener (2).
3. Clean armor plate (1) to remove adhesive.
I b. Installation
1. Peal paper backing (11) from sound dampener (2) and install sound dampener (2) on armor plate (1).
2. Install armor plate (1) on wheelhouse (3) with ten washers (4), capscrews (10), washers (4), and
locknuts (5). Tighten capscrews (10) to 6 lb-ft (8 N~m).
3. Install two footman (8) on wheelhouse (3) with four screws (9), washers (6), and locknuts (7).
11-58
TM 9-2320-280-20-3
11-39. RIGHT WHEELHOUSE ARMOR PLATE REPLACEMENT (Cont’d)
FOLLOW-ON TASKS: M1043, M1043A1, M1043A2, M1044, and M1044A1 only:

● Install machine gun stop (para. 11-100).
M1045, M1045A1, M1045A2, M1046, and M1046A1 only
. Install night sight support assembly (para. 11-82).
● Close cargo shell door (TM 9-2320-280-10).
11-59
TM 9-2320-280-20-3
11-40. LEFT WHEELHOUSE ARMOR PLATE REPLACEMENT

This task covers:
INITIAL SETUP:
M1025, M1025A1, M1025A2, M1026, TM 9-2320-280-10
M1026A1, M1043, M1043A1, M1043A2, TM 9-2320-280-24P
M1044, M1044A1, M1045, M1045A1,
M1045A2, M1046, M1046A1 Equiment Condition
● Rear end of cargo shell door raised
Tools (TM 9-2320-280-10).
General mechanic’s tool kit: M1045, M1045A1, M1045A2, M1046, and M1046A1
automotive (Appendix B, Item 1) only
● Tripod head mounting bracket removed
Ten locknuts (Appendix G, Item 58) M1043, M1043A1, M1043A2, M1044, and M1044A1
Sound dampener (Appendix G, Item 228) only
● Water can bumper removed (para. 11-109).
One mechanic
One assistant
1. Remove ten locknuts (2), washers (3), capscrews (7), washers (3), armor plate (5), and sound
dampener (4) from wheelhouse (1). Discard locknuts (2) and sound dampener (4).
b. Installation
1. Peel paper backing (6) from sound dampener (4) and install sound dampener (4) on armor plate (5).
2. Install armor plate (5) on wheelhouse (1) with ten washers (3), capscrews (7), washers (3), and
locknuts (2). Tighten capscrews (7) to 6 lb-ft (8 N.m).
FOLLOW-ON TASKS: M1043, M1043A1, M1043A2, M1044, and M1044A1 only

. Install water can bumper (para. 11-109).
M1045, M1045A1, M1045A2, M1046, and M1046A1 only
● Install tripod head mounting bracket (para. 11-79)
11-60
TM 9-2320-280-20-3
11-41. TAILGATE ARMOR PLATE REPLACEMENT

This task covers:
INITIAL SETUP:
All models except M996, M996A1, M997, Nine lockwashers (Appendix G, Item 110)
M997A1, M997A2, M998, M998A1, M1035, Sound dampener (Appendix G, Item 229)
M1035A1, M1035A2, M1037, M1038,
M1097A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) Tailgate lowered (TM 9-2320-280-10).
1. Remove nine capscrews (3), lockwashers (2), armor plate (1), and sound dampener (4) from
tailgate (5). Discard lockwashers (2) and sound dampener (4).
1. Peel paper backing (6) from sound dampener (4) and install sound dampener (4) on armor plate (1).
2. Install armor plate (1) on tailgate (5) with nine loclwashers (2) and capscrews (3). Tighten
capscrews (3) to 6 lb-ft (8 Nom).
FOLLOW-ON TASK: Raise and secure tailgate (TM 9-2320-280-10).
11-61
TM 9-2320-280-20-3
11-42. WEAPON STATION HATCH REPLACEMENT

This task covers:
INITIAL SETUP:
All models except M996, M996A1, M997, RTV Sealant (Appendix C, Item 38)
M997A1, M997A2, M998, M998A1, M1035, Locknut (Appendix G, Item 58)
M1035A1, M1035A2, M1037, M1038, M1038A1,
M1042, M1097, M1097A1, M1097A2
TM 9-2320-280-24P

1. Remove capscrew (6) and washer (7) from hatch pivot bracket (9) and weapon station (1).
2. Remove locknut (10), washer (5), capscrew (4), washer (5), and hatch pivot bracket (9) from weapon
station (1). Discard locknut (10).
3. Slide hatch hinge pin (3) out from hatch pivot bracket (2) and remove weapon station hatch (8).
b. Installation
NOTE
Some hatches may leak water. To prevent water leaks, install NSN 5330-01-190-2227
seal on hatch with RTV sealant.
1. Install weapon station hatch (8) with hatch hinge pin (3) in hatch pivot bracket (2).
2. Install hatch pivot bracket (9) on weapon station (1) with washer (5), capscrew (4), washer (5),
and locknut (10).
3. Install hatch pivot bracket (9) on weapon station (1) with washer (7) and capscrew (6). Tighten
locknut (10) and capscrew (6) to 37 lb-ft (50 N.m).
11-62
TM 9-2320-280-20-3
11-43. WEAPON STATION HATCH HANDLE REPLACEMENT

This task covers:
a. Removal b. installation
INITIAL SETUP:
M997A1, M997A2, M998, M998A1, M1035,
M1042, M1097, M1097A1, M1097A2 TM 9-2320-280-24P
Tools
Remove two locknuts (1), washers (2), capscrews (5), large washers (4), and handle (6) from hatch (3).
Install handle (6) on hatch (3) with two large washers (4), capscrews (5), washers (2), and locknuts (1).
Tighten locknuts to 6 lb-ft (8 N.m).
11-63
TM 9-2320-280-20-3
11-44. WEAPON STATION HATCH HINGE PIN REPLACEMENT

This task covers:
INITIAL SETUP:
All models except M996, M996A1, M997, Tw O locknuts (Appendix G, Item 106)
M997A1, M997A2, M998, M998A1, M1035,
M1042, M1097, M1097A1, M1097A2 TM 9-2320-280-24P
Tools
a. Removal
1. Remove two locknuts (3), washers (4), capscrews (7), and washers (4) from hatch hinge pin (5) and
hatch panel (1). Discard locknuts (3).
NOTE
Spacer not required on M1043, M1043A1, M1043A2, M1044, M1044A1,
M1045, M1045A1, M1045A2, M1046, and M1046A1 vehicles.
2. Remove hatch hinge pin (5) and two spacers (2) from hinge pivot bracket (6) and hatch panel (1).
b. Installation
1. Install hatch hinge pin (5) on hatch panel (1) and slide into hinge pivot bracket (6). Slide two
spacers (2) between hatch panel (1) and hinge pin (5) on top side of hatch panel (1).
2. Secure hatch hinge pin (5) to hatch panel (1) with two washers (4), capscrews (7), washers (4), and
11-64
TM 9-2320-280-20-3
11-45. WEAPON STATION HATCH HINGE REPLACEMENT

This task covers:
lNITIAL SETUP:
All models except M996, M996A1, M997, Sixteen locknuts (Appendix G, Item 58)
M997A1, M997A2, M998, M998A1, M1035,
M1042, M1097, M1097A1, M1097A2 TM 9-2320-280-24P
Tools
1. Remove seven locknuts (5), washers (2), capscrews (3), washers (2), right hatch panel (1),
and hinge (4) from left hatch panel (6). Discard locknuts (5).
2. Remove nine locknuts (11), washers (7), capscrews (8), washers (7), retainer (10), seal (9),
and hinge (4) from right hatch panel (1). Discard locknuts (11).
3. Inspect seal (9) for damage. Replace if damaged.
11-65
TM 9-2320-280-20-3
11-45. WEAPON STATION HATCH HINGE REPLACEMENT (Cont’d)

I
b. Installation
1. Install hinge (4), seal (5), and retainer (6) on right hatch panel (1) with nine washers (2), capscrews (3),
2. Install hinge (4) and right hatch panel (1) on left hatch panel (11) with seven washers (8), capscrews (9),
washers (8), and locknuts (10). Tighten locknuts (10) to 6 lb-ft (8 N~m).
11-66
TM 9-2320-280-20-3
11-46. WEAPON STATION HATCH HOLDDOWN STRIKER REPLACEMENT

This task covers:
lNITIAL SETUP:
M997A1, M997A2, M998, M998A1, M1035,
M1042, M1097, M1097A1, M1097A2 TM 9-2320-280-24P
Tools
NOTE
This task covers the left hatch panel holddown striker. The right
hatch panel holddown striker is mounted directly on the panel.
1. Remove two locknuts (5), washers (4), screws (1), and holddown striker (2) from bracket (3). Discard
locknuts (5).
2. Remove two locknuts (7), washers (8), capscrews (9), washers (8), and bracket (3) from left hatch
panel (6). Discard locknuts (7).
b. Installation
1. Install striker (2) on bracket (3) with two screws (1), washers (4), and locknuts (5).
2. Install bracket (3) on left hatch panel (6) with two washers (8). capscrews (9), washers (8),
and locknuts (7). Tighten locknuts (7) to 6 lb-ft (8 N-m). ‘
11-67
TM 9-2320-280-20-3
11-47. WEAPON STATION TRAY SEAL REPLACEMENT

This task covers:
INITAL SETUP:
All models except M996, M996A1, M997, Adhesive (Appendix C, Item 3)
M997A1 M997A2, M998, M998A1, M1035,
M1042, M1097, M1097A1, M1097A2 TM 9-2320-280-24P
Tools
1. Remove seal (1) from weapon station (2).

2. Thoroughly clean the edge of weapon station (2).
1. Measure and cut required length of seal (1).

2. Apply a 1/16-in. (1.6 mm) to 1/8-in. (3.2 mm) bead of adhesive to seal (1) lip.
3. Starting somewhere other than at a corner, press seal over the lip of the weapon station (2) tray
hatch opening.
4. Allow seal (1) to set and cure undisturbed, for about one hour.
11-68
TM 9-2320-280-20-3
1 1 - 4 8 . WEAPON STATION BUMPER PAD REPLACEMENT

This task covers:
INITIAL SETUP:
Applicable Models
Materials/Parts
All models except M996, M996A1,
M997, M997A1, M997A2, M998, M998A1, Locknut (Appendix G, Item 58)
M1035, M1035A1, M1035A2, M1037, M1038, Two rivets (Appendix G, Item 177.1)
M1097A2, M1123
TM 9-2320-280-24P
Tools
NOT E
• For instructions on replacement of rivets, refer to para. 10-66.
• Bumper pads for both sides of hatch are installed basically the
same. This procedure covers the right side.
a. Removal
NOT E
• Perform step 1 for old configuration vehicles.
• Perform step 2 for new configuration vehicles.
1. Remove locknut (5), washer (4), screw (3), and bumper pad (2) from hatch (1). Discard locknut (5).
2. Remove rivet (6) and bumper pad (2) from hatch (1).
b. Installation
NOT E
• Perform step 1 for old configuration vehicles.
• Perform step 2 for new configuration vehicles.
1. Install bumper pad (2) on hatch (1) with screw (3), washer (4), and locknut (5).
2. Install bumper pad (2) on hatch (1) with rivet (6).
OLD CONFIGURATION NEW CONFIGURATION
Change 1 11-69
TM 9-2320-280-20-3
1 1 - 4 9 . WEAPON STATION TRAY LEVER REPLACEMENT
This task covers:

INITIAL SETUP:
All models except M996, M996A1, Four spring washers (Appendix G, Item 235)
M997, M997A1, M997A2, M998, M998A1, Sealing compound (Appendix C, Item 40)
M1035, M1035A1, M1035A2, M1037, M1038,
M1097A2, M1123 TM 9-2320-280-24P
Tools
a. Removal
Remove capscrew (4), washer (3), two spring washers (2), tray lever (1), two spring washers (2), and
washer (3) from weapon station (5). Discard spring washers (2).
b. Installation
NOT E
Apply sealing compound to threads on capscrew.
Install washer (3), two spring washers (2), and tray lever (1) on weapon station (5) with two spring
washers (2), washer (3), and capscrew (4). Tighten capscrew (4) to 6 lb-ft (8 N•m).
11-70 Change 1
TM 9-2320-280-20-3
11-50. WEAPON STATION HATCH LATCH REPLACEMENT

This task covers:
lNITIAL SETUP:
All models except M996, M996A1, M997, General mechanic’s tool kit
M997A1, M997A2, M998, M998A1, M1035, automotive (Appendix B, Item 1)
M1035A1, M1035A2, M1037, M1038, M1038A1,
TM 9-2320-280-24P
NOTE
● Procedures for replacing the three hatch latches are basically
the same, except the hatch latch opposite the backrest side of
weapon station has a spacer. This procedure covers the hatch
latch with spacer.
● To increase latch tension, 3/8-in. (9.5 mm) flat washers may be
added between bottom of weapon station and any of the three
hatch latches.
Remove capscrew (2), washer(1), hatch latch (5), and spacer (4) from weapon station (3).
Install spacer (4) and hatch latch (5) on weapon station (3) with washer (1) and capscrew (2). Tighten
capscrew (2) to 37 lb-ft (50 N-m).
11-71
TM 9-2320-280-20-3
11-51. WEAPON STATION HATCH TUBE ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
Tools
Applicable Models General mechanic’s tool kit
All models except M996, M996A1, M997, automotive (Appendix B, Item 1)
M997A1, M997A2, M998, M998A1, M1035,
M1035A1, M1035A2, M1037, M1038, M1038A1, Materials/Parts
M1042, M1097, M1097A1, M1097A2 Ten locknuts (Appendix G, Item 106)
Manual References
TM 9-2320-280-24P
I a. Removal
I NOTE
l Note locations of capscrews for installation.
l Later production vehicles are equipped with spacers.
Remove ten locknuts (5), washers (1), capscrews (2), washers (1), hatch tube (4), and five spacers (6), if
installed, from weapon station (3). Discard locknuts (5).
I
b. Installation
(
NOTE
TOW mount pedestal and TOW MGS pan/armament cover and
armament mount panel must be in place prior to installing weapon
station hatch tube assembly.
Install five spacers (6), if removed, and hatch tube (4) on weapon station (3) with ten washers (1),
capscrews (2), washers (1), and locknuts (5). Tighten locknuts (5) to 37 lb-ft (50 N.m).
11-72
TM 9-2320-280-20-3
11-52. HINGE PIVOT BRACKET AND GUNNER’S SLING REPLACEMENT I

This task covers:
lNITIAL SETUP:
M997A1, M997A2, M998, M998A1, M1035,
M1038A1, M1042, M1097, M1097A1, M1097A2 TM 9-2320-280-24P
Tools
1. Remove locknut (8), washer (2), capscrew (3), washer (2), gunner’s sling (9), and hinge pivot
bracket (6) from weapon station (1). Discard locknut (8).
2. Remove capscrew (4), washer (5), and hinge pivot bracket (6) from weapon station (1) and rear hinge
pin (7).
1. Install hinge pivot bracket (6) on rear hinge pin (7).

2. Install hinge pivot bracket (6) on weapon station (1) with washer (5) and capscrew (4). Tighten
capscrew (4) to 37 lb-ft (50 N-m).
3. Install hinge pivot bracket (6) and gunner’s sling (9) on weapon station (1) with washer (2),
capscrew (3), washer (2), and locknut (8). Tighten locknut (8) to 37 lb-ft (50 N.m).
11-73
TM 9-2320-280-20-3
I 11-53. GUNNER’S SLING HOOK REPLACEMENT I

This task covers:
INITIAL SETUP:
M997A1, M997A2, M998, M998A1, M1035,
M1042, M1097, M1097A1, M1097A2 TM 9-2320-280-24P
Tools
a. Removal
Remove locknut (5), washer (2), capscrew (1), washer (2), and gunner’s sling hook (4) from weapon
Install gunner’s sling hook (4) on weapon station (3) with washer (2), capscrew (1), washer (2), and
locknut (5). Tighten locknut (5) to 37 lb-ft (50 N-m).
11-74
TM 9-2320-280-20-3
1 1 - 5 4 . WEAPON STATION BACKREST PAD REPLACEMENT
This task covers:

INITIAL SETUP:
M997A1, M997A2, M998, M998A1, M1035,
M1038A1, M1042, M1097, M1097A1,1097A2, TM 9-2320-280-24P
M1123
Tools
NOT E
The procedure for removing and installing left and right backrest
pads is the same. This procedure covers right backrest pad.
a. Removal
Remove three locknuts (4), washers (2), capscrews (3), washers (2), and backrest pad (5) from weapon
station (1). Discard locknuts (4).
b. Installation
Install backrest pad (5) on weapon station (1) with three washers (2), capscrews (3), washers (2),
and locknuts (4). Tighten locknuts (4) to 37 lb-ft (50 N•m).
Change 1 11-75
TM 9-2320-280-20-3
1 1 - 5 5 . TURRET HANDLE REPLACEMENT
This task covers:

INITIAL SETUP:
All models except M996, M996A1, Four locknuts (Appendix G, Item 76)
M997, M997A1, M997A2, M998, M998A1,
M1035, M1035A1, M1035A2, M1037, Manual References
M1038, M1038A1, M1042, M1097, TM 9-2320-280-24P
M1097A1, M1097A2, M1123
Tools
NOT E
• Fabrication instructions are available to replace the turret
handle. Refer to appendix D (fig. D-95).
• The following procedure is for replacement of turret handle that
has been previously removed and installed in accordance with
the fabrication instructions.
a. Removal
Remove four locknuts (4), washers (2), capscrews (1), washers (2), and turret handle (3) from weapon
station tray (5). Discard locknuts (4).
b. Installation
Install turret handle (3) on weapon station tray (5) with four washers (2), capscrews (1), washers (2),
and locknuts (4).
11-76 Change 1
TM 9-2320-280-20-3
11-56. TURRET LOCK REPLACEMENT

This task covers:
INITIAL SETUP:
M997A1, M997A2, M998, M998A1, M1035,
M1042, M1097, M1097A1, M1097A2 TM 9-2320-280-24P
Tools
Remove two locknuts (6), washers (1), capscrews (2), washers (1), turret lock (5), and spacer(s) (4) from
weapon station (3). Discard locknuts (6).
b. Installation I
NOTE
Install same amount of spacers that were removed between bottom
of weapon station and turret lock. Amount of spacers maybe
adjusted to correct lock handle binding. Refer to TM 9-2320-280-24P
if more spacers are needed.
Install spacer(s) (4) and turret lock (5) on weapon station (3) with two washers (1), capscrews (2),
11-77
TM 9-2320-280-20-3
1 1 - 5 7 . TOW MOUNT PEDESTAL REPLACEMENT
This task covers:

INITIAL SETUP:
Applicable Models Materials/Part
M966, M966A1, M1036, M1045, M1045A1, Eight locknuts (Appendix G, Item 106)
M1045A2, M1046, M1046A1, M1121
Manual References
Tools TM 9-2320-280-24P
a. Removal
NOT E
Note locations of capscrews for installation.
Remove eight locknuts (4), washers (2), capscrews (3), washers (2), and pedestal mount (1) from weapon
station (5). Discard locknuts (4).
b. Installation
Install pedestal mount (1) on weapon station (5) with eight washers (2), capscrews (3), washers (2), and
locknuts (4). Tighten locknuts (4) to 37 lb-ft (50 N•m).
11-78 Change 1
TM 9-2320-280-20-3
1 1 - 5 8 . TOW MOUNT PEDESTAL COVER REPLACEMENT
This task covers:

INITIAL SETUP:
M966, M966A1, M1036, M1045, Two locknuts (Appendix G, Item 58)
M1045A1, M1045A2, M1046, M1046A1, M1121
Manual References
Tools TM 9-2320-280-20P
a. Removal
Remove two locknuts (5), washers (1), capscrews (2), washers (1), and TOW mount pedestal cover (3)
from weapon station (4). Discard locknuts (5).
b. Installation
Install TOW mount pedestal cover (3) on weapon station (4) with two washers (1), capscrews (2),
washers (1), and locknuts (5). Tighten locknuts (5) to 65 lb-in. (7 N•m).
Change 1 11-79
TM 9-2320-280-20-3
1 1 - 5 9 . TOW MISSILE GUIDANCE SYSTEM PAN REPLACEMENT
This task covers:

INITIAL SETUP:
M966, M966A1, M1036, M1045, M1045A1, Five locknuts (Appendix G, Item 106)
M1045A2, M1046, M1046A1, M1121
Manual References
Tools TM 9-2320-280-24P
a. Removal
NOT E
1. Remove locknut (7), washer (6), washer (5), capscrew (4), and washer (3) from TOW MGS
pan (12) and weapon station (8). Discard locknut (7).
2. Remove four locknuts (9), washers (10), capscrews (2), washers (1), TOW MGS pan (12), and three
washers (11) from weapon station (8). Discard locknuts (9).
b. Installation
1. Install three washers (11) and TOW MGS pan (12) on weapon station (8) with four washers (1),
capscrews (2), washers (10), and locknuts (9).
2. Secure TOW MGS pan (12) to weapon station (8) with washer (3), capscrew (4), washer (5),
washer (6), and locknut (7).
3. Tighten locknuts (9) and (7) to 12 lb-ft (16 N•m).
11-80 Change 1
TM 9-2320-280-20-3
1 1 - 6 0 . WEAPON STATION INCLINOMETER REPLACEMENT
This task covers:

INITIAL SETUP:
M966, M966A1, M1036, M1045, M1045A1, TM 9-2320-280-24P
M1045A2, M1046, M1046A1, M1121
Tools
a. Removal
Remove two screws (4), washers (3), and inclinometer (1) from weapon station (2).
b. Installation
Install inclinometer (1) on weapon station (2) with two washers (3) and screws (4).
Change 1 11-81
TM 9-2320-280-20-3
1 1 - 6 1 . ARMAMENT MOUNTING ASSEMBLY REPLACEMENT
This task covers:

INITIAL SETUP:
M1025, M1025A1, M1025A2, M1026, M1026A1, Six locknuts (Appendix G, Item 106)
M1043, M1043A1, M1043A2, M1044, M1044A1
Manual References
Tools TM 9-2320-280-24P
a. Removal
NOT E
• Note locations of capscrews for installation.
• Later production vehicles are equipped with a spacer.
1. Remove pin (7) and adapter (3) from armament mounting assembly (4).
2. Remove six locknuts (5), washers (1), capscrews (2), washers (1), armament mounting assembly (4),
and spacers (6), if installed, from weapon station (8). Discard locknuts (5).
b. Installation
1. Install six spacers (6), if removed, and armament mounting assembly (4) on weapon station (8) with six
washers (1), capscrews (2), washers (1), and locknuts (5). Tighten locknuts (5) to 37 lb-ft (50 N•m).
2. Install adapter (3) on armament mounting assembly (4) with pin (7).
11-82 Change 1
TM 9-2320-280-20-3
11-62. ARMAMENT COVER AND SEAL REPLACEMENT

This task covers:
INITIAL SETUP:
M1025, M1025A1, M1025A2, M1026, M1026A1, Four locknuts (Appendix G, Item 106)
M1043; M1043A1, M1043A2, M1044, M1044A1
Manual References
Tools TM 9-2320-280-24P
NOTE
1. Remove locknut (6), washer (4), capscrew (3), and washer (4) from armament cover (5) and weapon
2. Remove three locknuts (7), washers (1), capscrews (2), washers (1), and armament cover (5) from
weapon station (8). Discard locknuts (7).
3. Remove seal (10) from armament cover (5). Clean armament cover (5) to remove adhesive.
b. Installation
1. Peel paper backing (9) from seal (10) and apply seal (10) to armament cover (5).
2. Install armament cover (5) on weapon station (8) with three washers (1), capscrews (2), washers (1),
and locknuts (7).
3. Secure armament cover (5) to weapon station (8) with washer (4), capscrew (3), washer (4), and
locknut (6).
4. Tighten locknut (6) to 65 lb-in. (7 N.m). Tighten locknuts (7) to 12 lb-ft (16 N-m).
11-83
TM 9-2320-280-20-3
11-63. GUNNER’S PLATFORM REPLACEMENT

This task covers:
INITIAL SETUP:
M997A1, M997A2, M998, M998A1, M1035, TM 9-2320-280-24P
M1035A1, M1035A2, M1037, M1038, M1038A1,
M1042, M1097, M1097A1, M1097A2
Tools
1. Remove four capscrews (3) and washers (2) from two guides (7) and remove four channel nuts (6)
from gunner’s platform (1).
2. Remove two pins (4) from gunner’s platform (1).
NOTE
Tag location of guides for installation.
3. Slowly lift front of gunner’s platform (1) and remove two guides (7) and four channel nuts (6) from
pin receptacles (8) on forward risers (5).
4. Tilt gunner’s platform (1) all the way back.
5. Remove two nuts (10), washers (11), and shoulder bolts (13) from rear brackets (12) and rear
risers (9) and remove gunner’s platform (1).
6. Remove footman loops and straps (para. 10-9) from gunner’s platform (1).
b. Installation
1. Install footman loops and straps (para. 10-9) on gunner’s platform (1).
2. Install rear brackets (12) on rear risers (9) and install gunner’s platform (1) with two shoulder
bolts (13), washers (11), and nuts (10). Tighten nuts (10) to 10-15 lb-ft (14-20 N-m).
3. Slide two channel nuts (6) in guides (7), align with front hole in guide (7), and hold in place.
4. Align two guides (7) with front holes in gunner’s platform (1). Place two washers (2) on cap-
screws (3) and install capscrews (3) through front holes in gunner’s platform (1) and guides (7)
into channel nuts (6). Tighten capscrews (3) finger tight.
5. Slide two pin receptacles (8) into guides (7).
6. Slide two rear channel nuts (6) into rear of guides (7), align with rear holes in gunner's platform (1) by
moving front of gunner’s platform (1) slightly up and down, and install washers (2) and capscrews (3) in
channel nuts (6).
7. Install two pins (4) on rear side holes, and tighten four capscrews (3) to 6 lb-ft (8 N.m).
11-84
TM 9-2320-280-20-3
11-63. GUNNER’S PLATFORM REPLACEMENT (Cont’d)
FOLLOW-ON TASK: Check operation of gunner’s platform (TM 9-2320-280-10).
11-85
TM 9-2320-280-20-3
11-64. GUNNER’S PLATFORM ASSEMBLY MAINTENANCE

This task covers:
a Disassembly b. Assembly
lNITIAL SETUP:
M1035A1, M1035A2, M1037, M1038, M1038A1,
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) ● Gunner’s platform removed (para. 11-63).
● Gunner’s platform assembly removed
Five locknuts (Appendix G, Item 80)
& Disassembly
1. Remove two nuts (5), washers (4), shoulder bolts (2), and outer risers (3) from rear mounting
bracket (6).
2. Remove riser assembly (1) from front mounting bracket (7).
3. Remove two nuts (9), washers (10), capscrews (17), spacers (12), outer risers (3), and latches (18)
from inner risers (11).
4. Remove two nuts (13), washers (14), capscrews (16), and two pin-and-lanyard assemblies (15) from
outer risers (3).
5. Remove four nuts (24), washers (23), capscrews (19), and inner risers (11) from stiffener plate (8).
6. Remove two nuts (20), washers (21), and guide pin bolts (22) from inner risers (11).
11-86
TM 9-2320-280-20-3
11-64. GUNNER’S PLATFORM ASSEMBLY MAINTENANCE (Cont’d)

TM 9-2320-280-20-3
11-64. GUNNER’S PLATFORM ASSEMBLY MAINTENANCE (Cont’d)
I b. Assembly
1. Install two guide pin bolts (17) on inner risers (4) with two washers (16) and nuts (15). Tighten
nuts (15) to 10-15 lb-ft (14-20 Nom).
NOTE
Make sure heads of guide pin bolts are installed inward, facing
each other.
2. Install inner risers (4) on stiffener plate (1) with four capscrews (14), washers (18), and nuts (19).
Tighten nuts (19) to 6 lb-ft (8 N-m).
3. Install two pin-and-lanyard assemblies (8) on outer risers (12), on same side as pin receptacles (13),
with two capscrews (9), washers (7), and nuts (6). Tighten nuts (6) to 6 lb-ft (8 N-m).
4. Install two spacers (5), outer risers (12), and latches (11) on inner risers (4) ensuring pin
receptacles (13) are facing outward, with two capscrews (10), washers (3), and nuts (2). Tighten
nuts (2) to 6 lb-ft (8 N.m), then back off nuts 1/4 to 1/2 turn to allow outer risers (12) to pivot freely.
5. Install guide pin bolts (17) on front mounting bracket (24) tracks, and install outer risers (12) on
rear mounting bracket (21) with two shoulder bolts (20), washers (22), and nuts (23). Tighten
nuts (23) to 10-15 lb-ft (14-20 N-m).
11-88
TM 9-2320-280-20-3
I 11-64. GUNNER’S PLATFORM ASSEMBLY MAINTENANCE (Cont’d)
FOLLOW-ON TASKS: ● Install gunner’s platform (para. 11-63).

● Install gunner’s platform assembly (para. 11-65).
11-89
TM 9-2320-280-20-3
11-65. GUNNER’S PLATFORM ASSEMBLY REPLACEMENT

This task covers:
lNITIAL SETUP:
All models except M996, M996A1, M997, Five locknuts (Appendix G, Item 80)
M997A1, M997A2, M998, M998A1, M1035,
M1035A1, M1035A2, M1037, M1038, M1038A1, Personnel Required
M1042, M1097, M1097A1, M1097A2 One mechanic
One assistant
Tools
a. Removal
1. Remove two locknuts (11), washers (9), reinforcement brackets (10), capscrews (8), and washers (9)
from front gunner’s platform bracket (7) and cargo floor (5). Discard locknuts (11).
2. Remove three locknuts (6), washers (3), capscrews (2), washers (3), gunner’s platform assembly (1), and
rear gunner’s bracket (4) from cargo floor (5). Discard locknuts (6).
b. Installation
1. Install gunner’s platform assembly (1) and rear gunner’s platform bracket (4) on cargo floor with
three washers (3), capscrews (2), washers (3), and locknuts (6).
2. Install front bracket (7) on cargo floor (5) with two washers (9), capscrews (8), reinforcement
brackets (10), washers (9), and locknuts (11). Tighten capscrews (2) and (8) to 21 lb-ft (29 N.m).
11-90
TM 9-2320-280-20-3
11-66. VEHICLE POWER CONDITIONER (VPC) MOUNTING BRACKET REPLACEMENT

This task covers:
INITIAL SETUP:
M966, M966A1, M1036, M1045, M1045A1, Four locknuts (Appendix G, Item 58)
M1045A2, M1046, M1046A1
Manual References
Tools TM 9-2320-280-24P
Remove four locknuts (5), washers (4), screws (1), and vehicle power conditioner (VPC) mounting bracket (3)
from underside of radio rack (2). Discard locknuts (5).
I b. Installation
Install VPC mounting bracket (3) on underside of radio rack (2) with four screws (1), washers (4), and
11-91
TM 9-2320-280-20-3
11-67. TOW WIRING HARNESS REPLACEMENT

This task covers:
INITIAL SETUP:
M966, M966A1, M1036, M1045, M1045A1, Grease (Appendix C, Item 24)
M1045A2, M1046, M1046A1 Tw O lockwashers (Appendix G, Item 108)
Twelve nut and lockwasher assemblies
Tools (Appendix G, Item 146)
General mechanic’s tool kit Manual References
TM 43-0139
TM 9-2320-280-24P
Equipment Condition
Battery ground cable disconnected (para. 4-73).
a. Removal
NOTE
Perform steps 1 through 3 for vehicles with serial numbers 99,999 and
below and step 4 for vehicles with serial numbers 100,000 and above.
1. Uncoil TOW wiring harness (9) and MGS power cable (7) from cable stowage cleat (10).
2. Remove nut and lockwasher assembly (3) and clamp (2) from TOW wiring harness (9), MGS power
cable (7), and support assembly (4). Discard nut and lockwasher aasembly (3).
3. Remove two nut and lockwasher assemblies (6), screws (1), and clamps (5) from TOW wiring
harness (9), MGS power cable (7), and “B” pillar (8). Discard nut and lockwasher assemblies (6).
5. Disconnect VPC cable (11) from connector receptacle (12).
6. Remove four nut and lockwasher assemblies (13), screws (16), cover (15), and connector
receptacle (12) from bracket (14). Discard nut and lockwasher assemblies (13).
7. Remove two nut and lockwasher assemblies (17), screws (19), and clamps (18) from TOW wiring
harness (9) and battery box (20). Discard nut and lockwasher assemblies (17).
11-92
TM 9-2320-280-20-3
11-67. TOW WIRING HARNESS REPLACEMENT (Cont’d)

I
11-93
TM 9-2320-280-20-3
NOTE
Perform steps 8 through 10 and 14 and 15 for vehicles with serial numbers
99,999 and below, and steps 11 through 15 for vehicles with serial numbers
100,000 and above with kits 5705623 and 5705624 installed.
8. Slide rubber boot (9) back to allow access to slave receptacle (3) connections.
9. Remove capscrew (1), lockwasher (2), slave positive cable (10), and lead 49B (11) from slave
receptacle (3). Discard lockwasher (2).
10. Remove capscrew (5), lockwasher (4), slave negative cable (6), and lead 50B (7) from slave
receptacle (3). Remove TOW wiring harness (8) from vehicle. Discard lockwasher (4).
11. Remove nut and lockwasher assembly (21), screw (23), and clamp (22) from TOW wiring
harness (8) and battery box (18). Discard nut and lockwasher assembly (21).
12. Remove capscrew (12), lockwasher (13), lead 50B (7), slave negative cable (6), and battery negative
cable (14) from shunt (15). Discard lockwasher (13).
13. Remove nut (20), lockwasher (19), lead 49B (11), cables (17), and slave positive cable (10) from power
stud (16). Discard lockwasher (19).
14. Remove two nut and lockwasher assemblies (32), screws (24), and clamps (25) from MGS power
cable (26), VPC cable (31), and body (27). Discard nut and lockwasher assemblies (32).
15. Remove two screws (29) from retainer (30) and body (27) and pull back insulation (28). Remove MGS
power cable (26) and VPC cable (31) from vehicle. -
b. Installation
1. Install MGS power cable (26) and VPC cable (31) on approximate mounting location in vehicle.
2. Install insulation (28) over MGS power cable (26) and VPC cable (31) and install retainer (30) to
body (27) with two screws (29).
3. Install VPC cable (31) and MGS power cable (26) on body (27) with two clamps (25), screws (24), and
nut and lockwasher assemblies (32).
4. Install TOW wiring harness (8) in approximate mounting location on vehicle.
NOTE
Perform steps 5 through 7 and 11 for vehicles with serial numbers
99,999 and below, and steps 8 through 10 for vehicles with serial
numbers 100,000 and above with kits 5705623 and 5705624
installed.
5. Connect lead 50B (7) and slave negative cable (6) to slave receptacle (3) with lockwasher (4)
and capscrew (5).
6. Connect lead 49B (11) and slave positive cable (10) to slave receptacle (3) with lockwasher (2) and
Capscrew (1).
7. Using grease, coat receptacle (3) terminals and all exposed metal on rear of receptacle (3) and area
under cap on front of receptacle (3).
8. Install lead 49B (11), slave positive cable (10), and cables (17) on power stud (16) with lock-
washer (19) and nut (20). Apply grease to power stud (16) and all exposed metal.
9. Install battery negative cable (14), slave negative cable (6), and lead 50B (7) on shunt (15) with
loclwasher (13) and capscrew (12).
10. Install TOW wiring harness (8) on battery box (18) with clamp (22), screw (23), and nut and
11. Slide rubber boot (9) to cover slave receptacle (3) connections.
11-94
TM 9-2320-280-20-3
11-95
TM 9-2320-280-20-3
WARNING
The battery box on some HMMWV TOW carrier models M966,
M966A1, M1045, M1045A1, M1045A2, M1046, or M1046A1 with
serial numbers 1 through 19,410 has cut through the TOW power
cable. A cut TOW power cable can cause a fire or battery explosion.
12. Inspect battery box (5) at comer where TOW wiring harness (2) exits battery box (5).
13. If the top edge of battery box (5) forms two “points” where the wiring harness (2) exits battery
box (5), (before), cut off the pointed comers and file round. Spot paint, if necessary (refer to
TM 43-0139). Battery box (5) should resemble (after) illustration when completed.
14. Install TOW wiring harness (2) on battery box (5) with two clamps (3), screws (4), and nut and
lockwasher assemblies (1).
NOTE
Cover chain is installed under lower right screw.
15. Install connector receptacle (7) and cover (15) on bracket (13) with four screws (16) and nut and
lockwasher assemblies (8).
16. Connect VPC cable (6) to connector receptacle (7).
NOTE
Perform steps 18 through 20 for vehicles with serial numbers
99,999 and below and step 17 for vehicles with serial numbers
100,000 and above.
17. Coil TOW wiring harness (2) and MGS power cable (10) around cable cleat (20).
18. Install TOW wiring harness (2) and MGS power cable (10) on “B” pillar (14) with two clamps (11),
screws (9), and nut and lockwasher assemblies (12).
19. Install TOW wiring harness (2) and MGS power cable (10) on support assembly (19) with clamp (17)
and nut and lockwasher assembly (18).
20. Coil TOW wiring harness (2) and MGS power cable (10) around cable stowage cleat (20).
11-96
TM 9-2320-280-20-3
11-97
TM 9-2320-280-20-3
11-68. CABLE STOWAGE CLEAT REPLACEMENT

This task covers:
INITIAL SETUP:
M966, M966A1, M1036, M1045, M1045A1, TM 9-2320-280-24P
M1045A2, M1046, M1046A1
Tools
NOTE
The cable stowage cleat for vehicles with serial numbers 100,000
and above is located behind the companion seat. Removal and
installation procedures are basically the same.
2. Remove two capscrews (4), washers (5), and cable stowage cleat (6) from support assembly (3).
1. Install cable stowage cleat (6) on support assembly (3) with twO washers (5) and capscrews (4).
2. Coil TOW wiring harness (1) and MGS power cable (2) around cable stowage cleat (6).
11-98
TM 9-2320-280-20-3
11-69. FIELD GLASSES BRACKET REPLACEMENT

This task covers:
lNITIAL SETUP:
M966, M966A1, M1036, M1045, M1045A1, Three locknuts (Appendix G, Item 58)
Tools TM 9-2320-280-24P
automotive (Appentix B, Item 1)
Remove three locknuts (4), washers (5), screws (2), and field glasses bracket (1) from radio rack
assembly (3). Discard locknuts (4).
Install field glasses bracket (1) on radio rack assembly (3) with three screws (2), washers (5), and
11-99
TM 9-2320-280-20-3
11-70. STOWAGE MOUNT BRACKET REPLACEMENT

This task covers:
INITIAL SETUP:
M1045A2, M1046, M1046A1 One assistant
Equipment Condition
Materials/Parts ● Stowage pedestal removed (para. 11-71).
Two locknuts (Appendix G, Item 106) ● Fuel tank removed (para. 3-24).
1. Remove two locknuts (5), washers (4), capscrews (17), and washers (4) from stowage mount
bracket (3) and support bracket (12). Discard locknuts (5).
2. Remove capscrew (8), washer (9), and tiedown (10) from stowage bracket (3) and cargo floor (16).
3. Slide plate (18) in “B” beam (14) to allow access to nut (13).
4. Remove nut (13), capscrew (6), and washer (7) from stowage bracket (3), spacer (11), and cargo
floor (16).
5. Remove nut (15), capscrew (2), washer (1), stowage bracket (3), and spacer (11) from cargo floor (16).
1. Install spacer (11) and stowage bracket (3) on cargo floor (16) with washer (1), capscrew (2),
and nut (15). Tighten capscrew (2) to 37 lb-ft (50 N.m).
2. Install stowage bracket (3) on cargo floor (16) with washer (7), capscrew (6), and nut (13). Tighten
capscrew (6) to 37 lb-ft (50 Nom).
3. Close plate (18) in “B” beam (14).
4. Secure stowage bracket (3) and tiedown (10) to cargo floor (16) with washer (9) and capscrew (8).
Tighten capscrew (8) to 75 lb-ft (102 N-m).
5. Install stowage bracket (3) on support bracket (12) with two washers (4), capscrews (17),
washers (4), and locknuts (5). Tighten locknuts (5) to 6 lb-ft (8 N-m).
11-100
TM 9-2320-280-20-3
11-70. STOWAGE MOUNT BRACKET REPLACEMENT (Cont’d)
FOLLOW-ON TASKS: . Install fuel tank (para. 3-24).

● Install stowage pedestal (para. 11-71).
11-101
TM 9-2320-280-20-3
11-71. STOWAGE PEDESTAL REPLACEMENT

This task covers:
INITIAL SETUP:
M966, M966A1, M1036, M1045, M1045A1, TM 9-1425-450-12
M1045A2, M1046, M1046A1 TM 9-1425-472-12
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) Traversing unit mount adapter removed
(TM 9-1425-450-12, TM 9-1425-472-12).
Materials/Parts
Remove eight locknuts (5), washers (3), capscrews (2), washers (3), and stowage pedestal (1) from
stowage mount bracket (4). Discard locknuts (5).
Install stowage pedestal (1) on stowage mount bracket (4) with eight washers (3), capscrews (2),
washers (3), and locknuts (5). Tighten capscrews (2) to 31 lb-ft (42 N*m).
FOLLOW-ON TASK Install traversing unit mount adapter (TM 9-1425-450-12, TM 9-1425-472-12).
11-102
TM 9-2320-280-20-3
11-72. TRAVERSING UNIT MOUNT ADAPTER MAINTENANCE

This task covers:
INITIAL SETUP:
M966, M966A1, M1036, M1045, M1045A1, TM 9-1425-450-12
M1045A2, M1046, M1046A1 TM 9-1425-472-12
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) Traversing unit mount adapter removed
(TM 9-1425-450-12, TM 9-1425-472-12).
Materials/Parts
NOTE
. Upper coupling clamp and lower coupling clamp are removed
and installed the same. This procedure covers the upper
coupling clamp.
. Note position of coupling clamp for installation.
a. Disassembly
Remove six locknuts (3), washers (4), capscrews (5), three retainers (6), and coupling clamp (1) from
traversing unit mount adapter (2). Discard locknuts (3).
Install coupling clamp (1) on traversing unit mount adapter (2) with three retainers (6), capscrews (5),
FOLLOW-ON TASK: Install traversing unit mount adapter (TM 9-1425-450-12, TM 9-1425-472-12).
11-103
TM 9-2320-280-20-3
11-73. ELEVATION AND DEPRESSION STOP ASSEMBLY MAINTENANCE

This task covers:
INITIAL SETUP:
M966, M966A1, M1036, M1045, M1045A1, TM 9-2320-280-24P
M1045A2, M1046, M1046A1
Tools Note position of downward stop and upward stop
General mechanic’s tool kit: for assembly.
Materials/Parts
Three retaining rings (Appendix G, Item 176)
WARNING
Note position of elevation and depression downward stop and
upward stop for assembly. Injury to personnel and/or damage to
equipment will result if stops are not properly assembled.
1. Remove retaining ring (3), clevis pin (15), cable end of pin assembly (14), and return spring (1) from
upward stop strap (4). Discard retaining ring (3).
2. Remove pin assembly (14) and upward stop bracket (2) from upward stop strap (4).
3. Remove retaining ring (6), clevis pin (9), cable end of pin assembly (10), and return spring (8) from
downward stop strap (11). Discard retaining ring (6).
4. Remove pin assembly (10) and downward stop bracket (7) from downward stop strap (11).
5. Remove retaining ring (16), clevis pin (5), socket head screw (12), and washer (13) from stop
straps (4) and (11). Discard retaining ring (16).
1. Install stop straps (4) and (11) together with clevis pin (5), retaining ring (16), washer (13), and
socket head screw (12).
2. Install downward stop bracket (7) on downward stop strap (11) with pin assembly (10) through
upper holes of downward stop bracket (7) and downward stop strap (11).
3. Install return spring (8), downward stop bracket (7), and cable end of pin assembly (10) on
downward stop strap (11) with clevis pin (9) and retaining ring (6).
4. Install upward stop bracket (2) on upward stop strap (4) with pin assembly (14) through upper holes
of upward stop bracket (2) and upward stop strap (4).
5. Install return spring (1), upward stop bracket (2), and cable end of pin assembly (14) on upward stop
strap (4) with clevis pin (15) and retaining ring (3).
11-104
TM 9-2320-280-20-3
11-73. ELEVATION AND DEPRESSION STOP ASSEMBLY MAINTENANCE (Cont’d)
11-105
TM 9-2320-280-20-3
11-74. M16 AMMO RACK ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
(TM 9-2320-280-10).
1. Remove four locknuts (7), washers (6), two reinforcement brackets (5), and four screws (4) from M16
ammo rack (2) and wheelhouse (1). Discard locknuts (7).
2. Remove two locknuts (8), washers (9), reinforcement brackets (10), screws (3), and M16 ammo
rack (2) from wheelhouse (1). Discard locknuts (8).
1. Install M16 ammo rack (2) on wheelhouse (1) with two screws (3), reinforcement brackets (10),
2. Secure M16 ammo rack (2) to wheelhouse (1) with four screws (4), twO reinforcement brackets (5),
four washers (6), and locknuts (7).
3. Tighten locknuts (7) and (8) to 6 lb-ft (8 N=m).
11-106
TM 9-2320-280-20-3
11-75. TOW MISSILE RACK MAINTENANCE

This task covers:
c. Inspection
INITIAL SETUP
Adhesive (Appendix C, Item 1) ● Rear end of cargo shell door raised
Sixteen cotter pins (Appendix G, Item 21) (TM 9-2320-280-10).
Twenty-five locknuts (Appendix G, Item 58) ● Tailgate lowered (TM 9-2320-280-10).
Six locknuts (Appendix G, Item 65) . Footman loop and strap removed (para. 10-9).
Eight nut and lockwasher assemblies
a. Removal
1. Remove two locknuts (16), washers (1), capscrews (2), and washers (1) from MGS battery
rack (3) and missile rack (4). Discard locknuts (16).
2. Remove three locknuts (7), washers (6), capscrews (5), and washers (6) from missile rack (4) and
cargo floor (8). Discard locknuts (7).
3. Remove two locknuts (13), washers (14), reinforcements (12), capscrews (15), and washers (14) from
missile rack (4) and cargo floor (8). Discard locknuts (13).
4. Remove capscrew (9), washer (10), missile rack (4), and tiedown (11) from cargo floor (8).
11-107
TM 9-2320-280-20-3
11-75. TOW MISSILE RACK MAINTENANCE (Cont’d)

I
b. Disassembly
1. Remove eight cotter pins (7), washers (8), pins (10), and four strap assemblies (9) from upper rack
assembly (4). Discard cotter pins (7).
2. Remove two locknuts (11), washers (12), capscrews (15), washers (12), spacers (13), and lanyard (24)
from upper rack assembly (4) and base assembly (21). Discard locknuts (11).
3. Release two tension latches (30) and raise upper rack assembly (4). Remove two cotter pins (17),
washers (18), pins (20), washers (18), torsion springs (19), washers (18), four washers (14), and
upper rack assembly (4) from base assembly (21). Discard cotter pins (17).
NOTE
Shims are installed under each bumper on front end of missile
rack, but only as needed under bumpers on rear end of missile rack.
4. Remove four locknuts (6), washers (5), capscrews (31), washers (5), four bumpers (41), and
shims (42) from upper rack assembly (4). Discard locknuts (6).
5. Remove four nut and lockwasher assemblies (43), washers (2), screws (1), washers (2), and two latch
strikes (3) from upper rack assembly (4). Discard nut and lockwasher assemblies (43).
6. Remove two cotter pins (32), washers (33), pins (40), and washers (33) from extension springs (35)
and base assembly (21). Disconnect extension springs (35) from spring brackets (34). Discard cotter
pins (32).
7. Remove two cotter pins (36), washers (39), pins (37), and upper supports (29) from intermediate rack
assemblies (25). Discard cotter pins (36).
8. Remove four nut and lockwasher assemblies (28), washers (23), screws (22), washers (23), and two
tension latches (30) from upper supports (29) Discard nut and lockwasher assemblies (28).
9. Remove two locknuts (26), washers (27), capscrews (16), washers (27), and connector bar (38)
from upper supports (29). Discard locknuts (26).
11-108
TM 9-2320-280-20-3
11-109
TM 9-2320-280-20-3
I 11-75. TOW MISSILE RACK MAINTENANCE (Cont’d)
10. Remove two cotter pins (16), washers (17), and pins (18) from intermediate supports (6). Release two
tension latches (21) and remove intermediate supports (6) and washers (13) from base assembly (27).
Discard cotter pins (16).
NOTE
11. Remove four locknuts (7), washers (8), capscrews (12), washers (8), bumpers (11), shims (10), and
two spring brackets (9) (outer side only) from intermediate supports (6). Discard locknuts (7).
12. Remove four locknuts (29), washers (2), screws (1), washers (2), and two latch strikes (3) from
intermediate rack assemblies (6). Discard locknuts (29).
13. Remove two locknuts (14), washers (5), capscrews (4), washers (5), and connector bar (15) from
intermediate rack assemblies (6). Discard locknuts (14).
14. Remove two locknuts (26), washers (24), capscrews (23), washers (24), and bracket (22) from base
15. Remove four locknuts (19), washers (20), screws (25), washers (20), and two tension latches (21)
from base assembly (27) and bracket (22). Discard locknuts (19).
NOTE
. Perform steps b. 16 and d. 1 if replacing missile pads.
● Procedures for replacing all missile pads are the same. Steps b. 16
and d. 1 cover replacement of one base assembly missile pad,
16. Remove pad (28) from base assembly (27), and clean remaining adhesive from base assembly (27)
mounting surface.
c. Inspection
1. Inspect base assembly (27), intermediate rack assemblies (6), and connector bars (15) for cracks,
broken welds, and damage. Replace any component if damaged.
2. Inspect bumpers (11) and missile pads (28) for cracks, tears, and deterioration. Replace any
component if damaged.
11-110
TM 9-2320-280-20-3
11-111
TM 9-2320-280-20-3
3. Inspect upper rack assembly (1) and upper supports (2) for cracks, broken welds, and damage.
Replace any component if damaged.
d. Assembly
1. Apply adhesive to base assembly (29) pad mounting surface and install missile pad (28) on base
assembly (29).
2. Install two tension latches (22) on base assembly (29) and bracket (23) with four washers (21),
3. Install bracket (23) on base assembly (29) with two washers (25), capscrews (24), washers (25),
4. Install connector bar (16) on two intermediate rack assemblies (8) with washers (7), capscrews (6),
5. Install two latch strikes (5) on intermediate rack assemblies (8) with four washers (4), screws (3),
NOTE
6. Install shims (12), four bumpers (13), and two spring brackets (9) (outer side only) on intermediate
rack assemblies (8) with four washers (11), capscrews (31), washers (11), and locknuts (10).
7. Install intermediate rack assemblies (8) and four washers (14) on base assembly (29) with
two pins (19), washers (18), and cotter pins (17). It maybe necessary to slowly install pins (19) while
installing washers (14) between intermediate rack assembly (8) sides and base assembly (29)
channels.
11-112
TM 9-2320-280-20-3
11-113
TM 9-2320-280-20-3
8. Connect two extension springs (36) to spring brackets (35). Extend springs (36) to base
assembly (21) and install with two washers (34), pins (41), washers (34), and cotter pins (33). Install
intermediate supports (25) on base assembly (21) with two lower tension latches (30).
9. Install connector bar (37) on upper supports (29) with two washers (27), capscrews (31),
10. Install two tension latches (30) on upper supports (29) with four washers (23), screws (22),
washers (23), and nut and lockwasher assemblies (28).
11. Install upper supports (29) on intermediate rack assemblies (25) with two pins (38), washers (40),
and cotter pins (39).
NOTE
12. Install shims (43) and four bumpers (42) on upper rack assembly (4) with four washers (5),
13. Install two latch strikes (3) on upper rack assembly (4) with four washers (2), screws (1),
washers (2), and nut and lockwasher assemblies (44).
14. Install upper rack assembly (4) and four washers (12) on base assembly (21) with two washers (18),
pins (20), torsion springs (19), washers (18), and cotter pins (17). It maybe necessary to slowly
install pins (20) while installing washers (12) between upper rack assembly (4) sides and base
assembly (21) channels.
15. Install lanyard (24) on upper rack assembly (4) and base asembly (21) with two washers (14),
capscrews (16), spacers (15), washers (14), and locknuts (13).
16. Install four strap assemblies (9) on upper rack assembly (4) with eight pins (10), washers (8),
and cotter pins (7).
17. Lift upper rack assembly (4) all the way up, and place one end of torsion springs (19) underneath
pad supports (11), and other end of torsion springs (19) on inner rack side of pins (41), ensuring
washers (34) are on outside of spring (19) ends. Lower upper rack assembly (4) and secure with two
tension latches (30).
11-114
TM 9-2320-280-20-3
11-115
TM 9-2320-280-20-3
e. Installation
1. Install tiedown (11) and missile rack (4) on cargo floor (8) with washer (10) and capscrew (9). Do not
tighten cascrew (9).
2. Secure missile rack (4) to cargo floor (8) with three washers (6), capscrews (5), washers (6), and
locknuts (7). Do not tighten capscrews (5).
3. Secure missile rack (4) to cargo floor (8) with two washers (13), capscrews (15), reinforcements (12),
washers (13), and locknuts (14). Do not tighten capscrews (15).
4. Install MGS battery rack (3) on missile rack (4) with two washers (1), capscrews (2), washers (1),
and locknuts (16). Tighten capscrews (2) to 6 lb-ft (8 N.m).
5. Tighten capscrews (5) and (15) to 21 lb-ft (28 N.m). Tighten capscrew (9) to 90 lb-ft (122 N.m).
FOLLOW-ON TASKS: ● Install footman loop and strap (para. 10-9).

● Raise and secure tailgate (TM 9-2320-280-10).
11-116
TM 9-2320-280-20-3
11-76. WATER CAN BUMPER REPLACEMENT

This task covers:
INITIAL SETUP:
M966, M966A1, M1036, M1045, M1045A1, TM 9-2320-280-10
M1045A2, M1046, M1046A1 TM 9-2320-280-24P

General mechanic’s tool kit Rear end of cargo shell door raised
Materials/Parts
TWO locknuts (Appendix G, Item 58)
Remove two locknuts (2), washers (3), capscrews (6), washers (3), water can bumper (5), and water can
bumper bracket (4) from MGS battery rack assembly (1). Discard locknuts (2).
b. Installation
Install water can bumper bracket (4) and water can bumper (5) on MGS battery rack assembly (1) with
two washers (3), capscrews (6), washers (3), and locknuts (2). Tighten locknuts (2) to 6 lb-ft (8 Nom).
11-117
TM 9-2320-280-20-3
11-77. MISSILE GUIDANCE SET (MGS) BATTERY RACK ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
Six locknuts (Appendix G, Item 58) . Rear end of cargo shell door raised
(TM 9-2320-280-10).
● Water can bumper removed (para. 11-76).
a Removal
1. Remove two locknuts (11), washers (2), capscrews (3), and washers (2) from MGS battery
rack (4) and missile rack (1). Discard locknuts (11).
2. Remove four locknuts (9), washers (5), reinforcement brackets (8) and (10), capscrews (6),
washers (5), and MGS battery rack (4) from wheelhouse (7). Discard locknuts (9).
3. Remove footman loop and strap (para. 10-9) from MGS battery rack (4).
b. Installation
1. Install footman loop and strap (para. 10-9) on MGS battery rack (4).
2. Install MGS battery rack (4) on wheelhouse (7) with four washers (5), capscrews (6), reinforcement
brackets (8) and (10), washers (5), and locknuts (9).
3. Install MGS battery rack (4) on missile rack (1) with two washers (2), capscrews (3), washers (2),
and locknuts (11). Tighten capscrews (3) and locknuts (9) to 6 lb-fl (8 Nom).
11-118
TM 9-2320-280-20-3
11-77. MISSILE GUIDANCE SET (MGS) BATTERY RACK ASSEMBLY REPLACEMENT (Cont’d)
FOLLOW-ON TASKS: ● Close cargo shell door (TM 9-2320-280-10).

● Install water can bumper (para. 11-76).
11-119
TM 9-2320-280-20-3
11-78. TRIPOD LEG MOUNTING BRACKET REPLACEMENT

This task covers:
lNITIAL SETUP:


Three locknuts (Appendix G, Item 58) . Rear end of cargo shell door raised
(TM 9-2320-280-10).
. Pioneer tool rack removed (TM 9-2320-280-10).
1. Remove three locknuts (9), washers (5), capscrews (6), washers (5), tripod leg bracket (4), and
spacers (10) from cargo floor (7). Discard locknuts (9).
2. Remove two nuts (11), washers (2), capscrews (1), washers (2), strap bracket (8), and strap (3) from
tripod leg bracket (4).
b. Installation
1. Install strap bracket (8) and strap (3) on tripod leg bracket (4) with two washers (2), capscrews (1),
washers (2), and nuts (11).
2. Install three spacers (10) and tripod leg bracket (4) on cargo floor (7) with three washers (5),
3. Tighten front and rear locknuts (9) and center capscrew (6) to 6 lb-ft (8 N-m).
FOLLOW-ON TASKS: . Close cargo shell door (TM 9-2320-280-10).

● Install pioneer tool rack (TM 9-2320-280-10).
11-120
TM 9-2320-280-20-3
11-79. TRIPOD HEAD MOUNTING BRACKET REPLACEMENT

This task covers:
INITIAL SETUP:
M966, M966A1, M1036, M1045, M1045A1, TM 9-2320-280-10
M1045A2, M1046, M1046A1 TM 9-2320-280-24P
General mechanic’s tool kit: ● Rear end of cargo shell door raised

c Tailgate lowered (TM 9-2320-280-10).
Materials/Parts
Three locknuts (Appendix G, Item 58)
NOTE
On M1045, M1045A1, M1045A2, M1046, and M1046A1 models, there is an
additional washer between the wheelhouse and the wheelhouse armor.
1. Remove three locknuts (7), washers (6), and plate assembly (5) from wheelhouse (8). Discard
locknuts (7).
2. Remove three capscrews (1), washers (2), tripod head bracket (3), and three spacers (4) from
wheelhouse (8)
I b. Installation
1. Install three spacers (4) and tripod head bracket (3) on wheelhouse (8) with three washers (2) and
capscrews (1).
2. Install plate assembly (5) on wheelhouse (8) with three washers (6) and locknuts (7). Tighten
locknuts (7) to 6 lb-ft (8 Nom).
FOLLOW-ON TASKS: . Raise and secure tailgate (TM 9-2320-280-10).

11-121
TM 9-2320-280-20-3
11-80. FUEL CAN TRAY AND HOSE REPLACEMENT

This task covers:
INITIAL SETUP:
M966, M966A1, M1036, M1045, M1045A1, TM 9-2320-280-10
M1045A2, M1046, M1046A1 TM 9-2320-280-24P
General mechanic’s tool kit: Rear of cargo shell door raised
automotive (Appendix B, Item 1) (’I’M 9-2320-280-10).
Materials/Parts
Screw (Appendix G, Item 208)
1. Remove screw (8) and hose clamp (6) from frame (5) and remove hose (7) from fuel can tray (3).
Discard screw (8).
2. Remove four screws (1), washers (2), and fuel can tray (3) from cargo floor (4).
b. Installation
1. Install fuel can tray (3) on cargo floor (4) with four washers (2) and screws (1). Tighten screws (1) to
6 lb-ft (8 Nom).
2. Connect hose (7) to fuel can tray (3).
3. Install hose (7) on frame (5) with clamp (6) and screw (8). Tighten screw (8) to 7 lb-ft (10 N.m).
11-122
TM 9-2320-280-20-3
11-81. DAY SIGHT STOWAGE BRACKET REPLACEMENT

This task covers:
INITIAL SETUP:
automotive (Appendix B, Item 1)) TM 9-2320-280-24P
Detergent (Appendix C, Item 17) Rear end of cargo shell door raised
Four locknuts (Appendix G, Item 58) (TM 9-2320-280-10).
Seven locknuts (Appendix G, Item 62)
1. Remove four locknuts (6), washers (5), capscrews (10), and bracket (2) from cargo floor (9). Discard
locknuts (6).
2. Remove seven locknuts (3), washers (4), capscrews (8), and two pads (1) from bracket (2). Discard
locknuts (3).
3. Inspect four spacers (7) in cargo floor (9) for damage. Replace any spacer (7) if damaged.
b. Installation
1. Lubricate pads (1) with detergent and install on bracket (2) with seven capscrews (8), washers (4),
and locknuts (3). Tighten locknuts (3) to 6 lb-ft (8 Nom).
2. Install bracket (2) on cargo floor (9) with four capscrews (10), washers (5), and locknuts (6).
11-123
TM 9-2320-280-20-3
11-82. NIGHT SIGHT SUPPORT REPLACEMENT

This task covers:
INITIAL SETUP:
(TM 9-2320-280-10).
Remove two locknuts (2), washers (3), capscrews (5), washers (3), and night sight support (4) from
Install night sight support (4) on wheelhouse (1) with two washers (3), capscrews (5), washers (3), and
11-124
TM 9-2320-280-20-3
11-83. NIGHT SIGHT COOLANT BASE REPLACEMENT

This task covers:
INITIAL SETUP:
(TM 9-2320-280-10).
1. Remove two locknuts (9), washers (6), spacers (8), capscrews (5), and washers (6) from night sight
coolant base (4) and cargo floor (7). Discard locknuts (9).
2. Remove two locknuts (10), washers (11), and screws (3) from coolant base (4) and cargo floor (7).
3. Remove two locknuts (12), washers (1), capscrews (2), washers (1), and coolant base (4) from cargo
floor (7). Discard locknuts (12).
b. Installation
1. Install coolant base (4) on cargo floor (7) with two washers (1), capscrews (2), washers (1), and
locknuts (12).
2. Secure coolant base (4) to cargo floor (7) with two screws (3), washers (11), and locknuts (10).
3. Secure coolant base (4) to cargo floor (7) with two washers (6), capscrews (5), spacers (8),
4. Tighten locknuts (10) to 50 lb-in. (6 N.m). Tighten locknuts (9) and (12) to 72 lb-in. (8 N.m).
11-125
TM 9-2320-280-20-3
11-84. FRONT NIGHT SIGHT BATTERY BRACKET REPLACEMENT

This task covers:
INITIAL SETUP:
Locknut (Appendix G, Item 58) Rear end of cargo shell door raised
Lockwasher (Appendix G, Item 126) (TM 9-2320-280-10).
1. Remove locknut (8), washer (1), reinforcement bracket (7), capscrew (2), and washer (1) from bracket (5)
and cargo floor (6). Discard locknut (8).
2. Remove capscrew (4), lockwasher (3), and bracket (5) from cargo floor (6) Discard lockwasher (3).
b. Installation
1. Install bracket (5) on cargo floor (6) with washer (1), capscrew (2), reinforcement
bracket (7), washer (1), and locknut (8).
2. Secure bracket (5) to cargo floor (6) with lockwasher (3) and capscrew (4).
3. Tighten capscrew (4) to 4 lb-ft (5 N-m). Tighten locknut (8) to 6 lb-ft (8 N-m).
11-126
TM 9-2320-280-20-3
11-85. REAR NIGHT SIGHT BATTERY BRACKET REPLACEMENT

This task covers:
INITIAL SETUP:
(TM 9-2320-280-10).
a. Removal
1. Remove locknut (7), washer (4), large washer (6), capscrew (3), and washer (4) from bracket (5) and
cargo floor (9). Discard locknut (7).
2. Remove locknut (8), washer (1), capscrew (2), washer (1), and bracket (5) from cargo floor (9).
1. Install bracket (5) on cargo floor (9) with washer (1), capscrew (2), washer (1), and locknut (8).
2. Secure bracket (5) to cargo floor (9) with washer (4), capscrew (3), large washer (6), washer (4), and
locknut (7). Tighten locknuts (7) and (8) to 6 lb-ft (8 N.m).
11-127
TM 9-2320-280-20-3
11-86. BORESIGHT COLLIMATOR OR NIGHT SIGHT MOUNTING SPACERS

REPLACEMENT
This task covers:
lNITIAL SETUP:
Four locknutS (Appendix G, Item 58) Rear end of cargo shell door raised
(TM 9-2320-280-10).
NOTE
Boresight collimator mounting spacers and night sight support
assembly mounting spacers are replaced the same. This procedure
covers the boresight collimator mounting spacers.
Remove four locknuts (5), washers (4), screws (1), and boresight collimator mounting spacers (2) from
Install four boresight collimator mounting spacers (2) on wheelhouse (3) with screws 1l), washers (4), and
locknuts (5). Tighten locknuts (5) to 6 lb-ft (8 Nom).
11-128
TM 9-2320-280-20-3
I 11-87. LAUNCH TUBE STOWAGE BRACKETS REPLACEMENT

This task covers:
lNITIAL SETUP:
M966, M966A1, M1036, M1045, M1045A1, TM 9-2320-280-10
M1045A2, M1046, M1046A1 TM 9-2320-280-24P
General mechanic’s tool kit Rear end of cargo shell door raised
Materials/Parts
Two cotter pins (Appendix G, Item 22)
1. Remove two cotter pins (5), pins (8), and strap (6) from front launch tube bracket (7) Discard cotter
pins (5).
2. Remove four locknuts (4), washers (3), front launch tube bracket (7), and plate (2) from cargo
3. Remove four capscrews (9), lockwashers (10), and rear launch tube bracket (11) from cargo
door (1). Discard lockwashers (10).
1. Apply sealing compound to threads of four capscrews (9). Install rear launch tube bracket (11) on
cargo door (1) with four lockwashers (10) and capscrews (9). Tighten capscrews (9) to 10 lb-ft (14 Nom)”
2. Install plate (2) and front launch tube bracket (7) on cargo door (1) with four washers (3) and
3. Install strap (6) on front launch tube bracket (7) with two pins (8) and cotter pins (5).
11-129
TM 9-2320-280-20-3
11-88. ANTENNA BLAST SHIELD REPLACEMENT 1

This task covers:
INITIAL SETUP:
M966, M966A1, M1036, M1045, M1045A1, TM 9-2320-280-10
M1045A2, M1046, M1046A1 TM 9-2320-280-24P
General mechanic’s tool kit: Rear end of cargo shell door raised
Materials/Parts
Remove four locknuts (5), washers (4), capscrews (2), washers (3), and blast shield (1) from cargo shell (6).
b. Installation
Install blast shield (1) on cargo shell (6) with four washers (3), capscrews (2), washers (4), and
locknuts (5). Tighten locknuts (5) to 85-110 lb-in. (10-12 Nom).
11-130
TM 9-2320-280-20-3
11-89. GASOLINE COOK STOVE BRACKET ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
Applicable Models
M966, M966A1, M1025, M1025A1, M1025A2, Sealing compound (Appendix C, Item 45)
M1026, M1026A1, M1036, M1045, M1045A1,
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) Remove engine right splash shield (para. 10-20).
Remove two capscrews (3), washers (2), and bracket assembly (1) from right airlift bracket (4).
1. Apply sealing compound to threads of two capscrews (3).

2. Install bracket assembly (1) on right airlift bracket (4) with two washers (2) and capscrews (3).
Tighten capscrews (3) to 6 lb-ft (8 Nom).
FOLLOW-ON TASK: Install engine right splash shield (para. 10-20).
11-131
TM 9-2320-280-20-3
1 1 - 9 0 . RIFLE SUPPORT REPLACEMENT
This task covers:

INITIAL SETUP:
M997A1, M997A2, M998, M998A1, M1035,
M1035A1, M1035A2, M1037, M1038, Personnel Required
M1038A1, M1042, M1097, M1097A1, One mechanic
M1097A2, M1123 One assistant
a. Removal
Remove three locknuts (5), washers (2), capscrews (1), washers (2), and rifle support (3) from floor
panel (4). Discard locknuts (5).
b. Installation
Install rifle support (3) on floor panel (4) with three washers (2), capscrews (1), washers (2), and
locknuts (5). Tighten locknuts (5) to 12-17 lb-ft (16-23 N•m).
11-132 Change 1
TM 9-2320-280-20-3
1 1 - 9 1 . RIFLE MOUNTING CLAMP REPLACEMENT
This task covers:

INITIAL SETUP:
M997A1, M997A2, M998, M998A1, M1035, Two locknuts (new configuration)
M1038A1, M1042, M1097, M1097A1,
M1097A2, M1123 Manual References
TM 9-2320-280-24P
Tools
NOT E
• Procedures for replacing the left and right rifle mounting clamps
are basically the same. This procedure covers the right rifle
mounting clamp.
• Vehicle may be equipped with new rifle mounting clamp bracket
configuration for M16 rifle or M203 grenade launcher.
a. Removal
Remove two locknuts (2), washers (3), screws (4), washers (3), and clamp (5) from clamp bracket (1).
b. Installation
Install clamp (5) on clamp bracket (1), with moveable finger (6) inboard, with two washers (3),
Change 1 11-133
TM 9-2320-280-20-3
1 1 - 9 2 . RIFLE MOUNTING CLAMP BRACKET REPLACEMENT
This task covers:

INITIAL SETUP:
M997A1, M997A2, M998, M998A1, M1035, Two locknuts (Appendix G, Item 98)
M1035A1, M1035A2, M1037, M1038, M1038A1,
M1042, M1097, M1097A1,M1097A2, M1123 Manual References
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) Rifle mounting clamp removed (para. 11-91).
NOT E
Replacement procedures for the front and rear (rear bracket installed on
M1025, M1025A1, M1025A2, M1026, M1026A1, M1043, M1043A1, M1043A2,
M1044, and M1044A1 vehicles only) rifle mounting clamp brackets are
basically the same. This procedure covers the right front and right rear
bracket (M1025A2 only).
a. Removal
1. Remove two locknuts (5), washers (3), capscrews (4), washers (3), and clamp bracket (2) from
“A” beam (1). Discard locknuts (5).
NOTE
Perform step 2 for M1025A2 vehicles only.
2. Remove two locknuts (6), washers (7), capscrews (9), washers (7), and clamp bracket (8) from
“B” pillar (10). Discard locknuts (6).
b. Installation
1. Install clamp bracket (2) on “A” beam (1) with two washers (3), capscrews (4), washers (3), and
locknuts (5).
NOTE
Perform step 2 for M1025A2 vehicles only.
2. Install clamp bracket (8) on “B” pillar (10) with two washers (7), capscrews (9), washers (7), and
locknuts (6).
11-134 Change 1
TM 9-2320-280-20-3
1 1 - 9 2 . RIFLE MOUNTING CLAMP BRACKET REPLACEMENT (Cont’d)
FOLLOW-ON TASK: Install rifle mounting clamp (para. 11-91).
Change 1 11-134.1/(11-134.2 blank)

TM 9-2320-280-20-3
11-93. RIFLE MOUNTING CLAMP BRACKET REPLACEMENT

(M16 A1 RIFLE/M203 GRENADE LAUNCHER)
This task covers:
INITIAL SETUP:
All models except M996, M996A1, M997, Cotter pin (Appendix G, Item 25)
M997A1, M997A2, M998, M998A1, M1035, Lockwasher (Appendix G, Item 110)
M1035A1, M1035A2, M1037, M1038, M1038A1, Two locknuts (Appendix G, Item 58)
M1042, M1097, M1097A1, M1097A2
Manual References
Took TM 9-2320-280-24P
Rifle mounting clamp removed (para. 11-91).
NOTE
Replacement procedures for left and right rifle mounting clamp
brackets are basically the same. This procedure covers the right
rifle mounting clamp bracket.
1. Remove cotter pin (7) from handle (5). Discard cotter pin (7).
2. Remove handle (5), lockwasher (4), washer (3), and clamp bracket (2) from mounting bracket (6).
3. Remove two locknuts (10), washers (8), capscrews (9), washers (8), and mounting bracket (6)
from “A” beam (1). Discard locknuts (10).
1. Install mounting bracket (6) on “A” beam (1) with two washers (8), capscrews (9), washers (8), and
locknuts (10).
2. Install clamp bracket (2) on mounting bracket (6) with washer (3), lockwasher (4), and handle (5).
3. Install cotter pin (7) on handle (5).
FOLLOW-ON TASK: Install rifle mounting clamp (para. 11-91).
11-135
TM 9-2320-280-20-3
11-94. LOWER RIFLE MOUNT BRACKET REPLACEMENT

This task covers:
lNITIAL SETUP:
M1025, M1025A1, M1025A2, M1026, General mechanic’s tool kit:
M1026A1, M1043, M1043A1, M1043A2, automotive (Appendix B, Item 1)
M1044, M1044A1, Manual References
TM 9-2320-280-24P
Remove two screws (4), washers (3), and lower rifle mount bracket (2) from “B” beam (1).
Install rifle mount bracket (2) on “B” beam (1) with two washers (3) and screws (4).
11-136
TM 9-2320-280-20-3
11-95. GUN ADAPTER PLATE ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
Applicable Models Peraonnel Required
M1044A1 One assistant
Materials/Parts
1. Remove two capscrews (2) and washers (1) from adapter plate (5) and cargo floor (11).
2. Remove locknut (14), washer (4), capscrew (3), and washer (4) from adapter plate (5) and cargo
floor (11). Discard locknut (14).
3. Remove locknut (12), washer (6), reinforcement bracket (13), capscrew (7), and washer (6) from
adapter plate (5) and cargo floor (11). Discard locknut (12).
4. Remove capscrew (8), washer (9), adapter plate (5), and cargo tiedown (10) from cargo floor (11).
b. Installation
1. Install cargo tiedown (10) and adapter plate (5) on cargo floor (11) with washer (9) and capscrew (8).
2. Install adapter plate (5) on cargo floor (11) with washer (6), capscrew (7), reinforcement bracket (13),
3. Secure adapter plate (5) to cargo floor (11) with washer (4), capscrew (3), washer (4), and
locknut (14).
4. Secure adapter plate (5) to cargo floor (11) with two washers (1) and capscrews (2).
5. Tighten capscrews (2), (7), and (3) to 6 lb-ft (8 N.m). Tighten capscrew (8) to 75 lb-ft (102 Nom).
11-137
TM 9-2320-280-20-3
11-96. FRONT GUN MOUNT PLATE ASSEMBLY REPLACEMENT

This task covers:
I
INITIAL SETUP:
M1044, M1044A1
Manual References
Tools TM 9-2320-280-10
Equipment Condition
Matenals/Parts ● Rear end of cargo shell door raised
Five locknuts (Appendix G, Item 107) (TM 9-2320-280-10).
● Fuel tank removed (para 3-24).
1. Remove five locknuts (5), washers (2), capscrews (1), washers (2), and front plate
assembly (3) from cargo floor (4) Discard locknuts (5).
2. Remove 40 mm gun mount support (para. 11-99) and caliber .50 gun mount support (para. 11-98)
from front plate assembly (3).
b. Installation
1. Install caliber .50 gun mount support (para. 11-98) and 40 mm gun mount support (para. 11-99) on
front plate assembly (3).
2. Install front plate assembly (3) on cargo floor (4) with five washers (2), capscrews (1), washers (2),
and locknuts (5). Tighten capscrews (1) to 26 lb-ft (35 N-m). .
FOLLOW-ON TASKS: . Close cargo shell door (TM 9-2320-280-10).

c Install fuel tank (para. 3-24).
11-138
TM 9-2320-280-20-3
11-97. REAR GUN MOUNT PLATE ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
M1044, M1044A1
Manual References
Tools TM 9-2320-280-10
Equipment Condition
Materials/Parts Rear end of cargo shell door raised
Six locknuts (Appendix G, Item 106) (TM 9-2320-280-10).
1. Remove three locknuts (7), washers (3), reinforcement brackets (6), capscrews (2), and washers (3)
from rear plate assembly (4) and cargo floor (5). Discard locknuts (7).
2. Remove three locknuts (8), washers (9), capscrews (1), washers (9), and rear plate assembly (4) from
3. Remove 40 mm gun mount support (para. 11-99) and caliber .50 gun mount support (para. 11-98)
from rear plate assembly (4).
b. Installation
1. Install caliber .50 gun mount support (para. 11-98) and 40 mm gun mount support (para. 11-99) on
rear plate assembly (4).
2. Install rear plate assembly (4) on cargo floor (5) with three washers (3), capscrews (2), reinforcement
brackets (6), washers (3), and locknuts (7).
3. Secure rear plate assembly (4) to cargo floor (5) with three washers (9), capscrews (1), washers (9),
and locknuts (8). Tighten capscrews (1) and (2) to 26 lb-ft (35 N~m).
11-139
TM 9-2320-280-20-3
11-98. GUN MOUNT SUPPORT (CALIBER .50) REPLACEMENT

This task covers:
INITIAL SETUP:
M1025, M1025A1, M1025A2, M1026, Two locknuts (Appendix G, Item 58)
M1026A1, M1043, M1043A1, M1043A2,
M1044, M1044A1 Manual References
TM 9-2320-280-10
Tools TM 9-2320-280-24P
(TM 9-2320-280-10).
1. Remove two locknuts (1), washers (2), capscrews (7), washers (2), and pad (3) from bracket (6).
2. Remove four capscrews (5), washers (4), and bracket (6) from mounting plate (8).
1. Install bracket (6) on mounting plate (8) with four washers (4) and capscrews (5). Tighten
capscrews (5) to 26 lb-ft (35 N=m).
2. Install pad (3) on bracket (6) with two washers (2), capscrews (7), washers (2), and locknuts (1).
Tighten locknuts (1) to 6 lb-ft (8 N.m).
11-140
TM 9-2320-280-20-3
11-99. GUN MOUNT SUPPORT (40 MM) REPLACEMENT I

This task covers:
INITIAL SETUP:
M1025. M1025A1, M1025A2, M1026, Four locknuts (Appendix G, Item 58)
M1026A1, M1043; M1043A1; M1043A2,
M1044, M1044A1 Manual References
TM 9-2320-280-10
TM 9-2320-280-24P
(TM 9-2320-280-10).
a. Removal
1. Remove four capscrews (11), washers (10), and bracket (12) from mounting plate (7).
2. Remove two locknuts (8), washers (3), capscrews (4), washers (3), and pad (1) from brace (9) and
3. Remove two locknuts (2), washers (6), screws (5), and brace (9) from bracket (12). Discard
locknuts (2).
b. Installation
1. Install brace (9) on bracket (12) with two screws (5), washers (6), and locknuts (2). Tighten
locknuts (2) to 6 lb-ft (8 N~m).
2. Install pad (1) on bracket (12) and brace (9) with Two washers (3), capscrews (4), washers (3), and
locknuts (8). Tighten locknuts (8) to 6 lb-ft (8 N=m).
3. Install bracket (12) on mounting plate (7) with four washers (10) and capscrews (11). Tighten
capscrews (11) to 26 lb-ft (35 N-m).
11-141
TM 9-2320-280-20-3
11-100. MACHINE GUN STOP REPLACEMENT

This task covers:
lNITIAL SETUP:
M1044, M1044A1
Tools TM 9-2320-280-10
Equipment Condition
Two locknuts (Appendix G, Item 58) (TM 9-2320-280-10).
Remove two locknuts (4), washers (2), capscrews (1), washers (2), and stop (3) from wheelhouse (5).
Install stop (3) on wheelhouse (5) with two washers (2), capscrews (1), washers (2), and locknuts (4).
Tighten locknuts (4) to 6 lb-ft (8 N.m).
11-142
TM 9-2320-280-20-3
I 11-101. NIGHT SIGHT RETAINER REPLACEMENT

This task covers:
lNITIAL SETUP:
M1025, M1025A1, M1025A2, M1026, TM 9-2320-280-10
M1026A1. M1043. M1043A1, M1043A2, TM 9-2320-280-24P
M1044, M1044A1
Equipment Condition
Tools Rear end of cargo shell door raised
General mechanic’s tool kit: (TM 9-2320-280-10).
Remove two screws (3), footman loop (2), and retainer (1) from wheelhouse (4).
Install retainer (1) and footman loop (2) on wheelhouse (4) with two screws (3).
11-143
TM 9-2320-280-20-3
I 11-102. TRIPOD BRACKET REPLACEMENT

This task covers:
INITIAL SETUP
M1044, M1044A1
Manual References
Tools TM 9-2320-280-10
automotive (appendix B, Item 1)
Equipment Condition
1. Remove locknut (8), washer (4), large washer (7), capscrew (3), and washer (4) from tripod
bracket (5) and cargo floor (6). Discard locknut (8).
2. Remove locknut (9), washer (1), capscrew (2), washer (1), and tripod bracket (5) from cargo floor (6).
1. Install tripod bracket (5) on cargo floor (6) with washer (1), capscrew (2), washer (1), and locknut (9).
2. Secure tripod bracket (5) to cargo floor (6) with washer (4), capscrew (3), large washer (7),
washer (4), and locknut (8). Tighten locknuts (8) and (9) to 6 lb-ft (8 N.m).
11-144
TM 9-2320-280-20-3
I 11-103. DOUBLE AMMO BOX TRAY (CALIBER .50) REPLACEMENT

This task covers:
INITIAL SETUP
M1044, M1044A1
Manual References
Tools TM 9-2320-280-10
Equipment Condition
1. Remove two locknuts (9), washers (2), capscrews (3), and washers (2) from ammo box tray (1) and
2. Remove two locknuts (8), washers (5), reinforcement brackets (7), capscrews (4), washers (5), and
ammo box tray (1) from wheelhouse (6). Discard locknuts (8).
1. Install ammo box tray (1) on wheelhouse (6) with two washers (5), capscrews (4), reinforcement
2. Secure ammo box tray (1) to wheelhouse (6) with two washers (2), capscrews (3), washers (2), and
locknuts (9). Tighten locknuts (9) and (8) to 6 lb-ft (8 N-m).
11-145
TM 9-2320-280-20-3
I 11-104. AMMO BOX TRAY (CALIBER .50) REPLACEMENT

This task covers:
INITIAL SETUP:
M1044, M1044A1
Manual References
Tools TM 9-2320-280-10
Equipment Condition
Remove four locknuts (6), washers (3), reinforcement brackets (5), capscrews (4), washers (3), and ammo
box tray (2) from wheelhouse (1). Discard locknuts (6).
b. Installation
Install ammo box tray (2) on wheelhouse (1) with four washers (3), capscrews (4), reinforcement
brackets (5), washers (3), and locknuts (6). Tighten capscrews (4) to 6 lb-it (8 N.m).
11-146
TM 9-2320-280-20-3
I 11-105. AMMO BOX TRAY (40 MM AND CALIBER .50) REPLACEMENT I

This task covers:
INITIAL SETUP
Applicable Models Peraonne[ Required
M1044, M1044A1
Manual References
Tools TM 9-2320-280-10
automotive (appendix B, item 1)
Equipment Condition
Matenals/Parta Rear end of cargo shell door raised
Four locknuts (Appendix G, Item 58) (TM 9-232O-28O-1O).
I a. Removal I
1. Remove locknut (7), washer (2), reinforcement bracket (8), capscrew (3), and washer (2) from
ammo box tray (1) and cargo floor (9). Discard locknut (7).
2. Remove three locknuts (6), washera (5), capscrews (4), washera (5), and ammo box tray (1)
from cargo floor (9). Discard locknuts (6).
I b. Installation I
NOTE
Longer capscrews go in right side mounting holes.
1. Install ammo box tray (1) on cargo floor (9) with washer (2), capscrew (3), retiorcement bracket (8),
2. Secure ammo box tray (1) to cargo floor (9) with three washers (5), capscrews (4), washers (5), and
locknuts (6). Tighten capscrews (4) and (3) to 6 lb-fi (8 N.m).
FOLLOW-ON TASK Close cargo shell door (TM 9-2320-280-10).
11”147
TM 9-2320-280-20-3
11-106. DOUBLE AMMO BOX TRAY (40 MM) REPLACEMENT

This task covers
INITIAL SETUP:
M1044, M1044A1
Manual References
Tools TM 9-2320-280-10
Equipment Condition
Eight locknuts (Appendix G, Item 58) (TM 9-2320-280-10).
Remove eight locknuts (5), washers (2), reinforcement brackets (4), capscrews (3), washers (2), and
ammo box tray (1) from cargo floor (6). Discard locknuts (5).
Install ammo box tray (1) on cargo floor (6) with eight washers (2), capscrews (3), reinforcement
brackets (4), washers (2), and locknuts (5). Tighten capscrews (3) to 6 lb-ft (8 N.m).
11-148
TM 9-2320-280-20-3
11-107. TRIPLE AMMO BOX TRAY (40 MM) REPLACEMENT

This task covers:
INITIAL SETUP:
M1044, M1044A1
Manual References
Tools TM 9-2320-280-10
Equipment Condition
Six locknuts (Appendix G, Item 58) (TM 9-2320-280-10).
1. Remove three locknuts (8), washers (2), capscrews (3), and washers (2) from ammo box tray (1) and
2. Remove three locknuts (7), washers (4), reinforcement brackets (6), capscrews (5), washers (4), and
ammo box tray (1) from cargo floor (9). Discard locknuts (7).
I b. Installation
1. Install ammo box tray (1) on cargo floor (9) with three washers (4), capscrews (5), reinforcement
2. Secure ammo box tray (1) to cargo floor (9) with three washers (2), capscrews (3), washers (2), and
locknuts (8). Tighten capscrews (3) and (5) to 6 lb-ft (8 N.m).
11-149
TM 9-2320-280-20-3
11-108. WATER CAN TRAY REPLACEMENT

This task covers:
INITIAL SETUP:
M1025, M1025A1, M1025A2, M1026, TM 9-2320-280-10
M1026A1, M1043, M1043A1, M1043A2, TM 9-2320-280-24P
M1044, M1044A1
Equipment Condition
Tools Rear of cargo shell door raised
Personnel Required
One mechanic
One assistant
NOTE
For M1025; M1025A1, M1025A2, M1026, and M1026A1 vehicles,
go to step 2.
1. Remove four screws (2), washers (3), and water can tray (1) from cargo floor (5).
2. Remove three screws (2), washers (3), and water can tray (1) from cargo floor (5).
3. Inspect rivnuts (4) for damage. Replace if damaged.
b. Installation
NOTE
For M1025, M1025A1, M1025A2, M1026, and M1026A1 vehicles,
go to step 2.
1. Install water can tray (1) on cargo floor (5) with four washers (3) and screws (2). Tighten screws (2)
to 6 lb-ft (8 N.m).
2. Install water can tray (1) on cargo floor (5) with three washers (3) and screws (2). Tighten screws (2)
to 6 lb-ft (8 N=m).
11-150
TM 9-2320-280-20-3
11-109. WATER CAN/M13 DECON CAN BUMPER REPLACEMENT I

This task covers:
a. Removal b. Iastallation
lNITIAL SETUP:
M1044, M1044A1
Manual References
Tools TM 9-2320-280-24P
automotive (appendix B, Item 1)
Equipment Condition
Materials/Parts Rear of cargo shell door raised
NOTE
● M1025, M1025A1, M1025A2, M1026, and M1026A1 vehicles
have both a water can and M13 decon can bumpers.
● M1043, M1043A1, M1043A2, M1044, and M1044A1 vehicles
have only a water can bumper.
a. Removal I
Remove two locknuts (4), screws (3), and water can bumper (2) from wheelhouse (1). Discard locknuts (4).
Install water can bumper (2) on wheelhouse (1) with two screws (3) and locknuts (4).
11-151
TM 9-2320-280-20-3
I 11-110. REAR SEAT STOWAGE COMPARTMENT NET BRACKETS REPLACEMENT

This task covers:
INITIAL SETUP:
M1025A2, M1043A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) Rear seat stowage compartment net removed
(TM-9-2320-280-10).
a. Removal
1. Remove two nuts (5), capscrews (7), and bracket (6) from support (4).
2. Remove two nuts (8), capscrews (3), washers (2), and bracket (1) from support (4).
I b. Installation
1. Install bracket (1) on support (4) with two washers (2), capscrews (3), and nuts (8).
2. Install bracket (6) on support (4) with two capscrews (7) and nuts (5).
FOLLOW-ON TASK: Install rear seat stowage compartment net (TM-9-2320-280-10).
11-152
TM 9-2320-280-20-3
11-111. CARGO BULKHEAD REPLACEMENT

This task covers:
INITIAL SETUP:
M1025A2, M1043A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
Equipment Condition
automotive (Appendix B, Item 1) Stowage compartment net removed
(TM 9-2320-280-10).
Materials/Parts
a. Removal
1. Remove cargo bulkhead (4) from two channels (5).

2. Remove four locknuts (2), hex head screws (3), and two channels (5) from wheel housings (1).
b. Installation
1. Install two channels (5) on wheel housings (1) with four hex head screws (3) and locknuts (2).
2. Tighten locknuts (2) to 15 lb-ft (20 N.m).
3. Install cargo bulkhead (4) in two channels (5).
FOLLOW-ON TASK: Install stowage compartment net (TM 9-2320-280-10).
11-153
TM 9-2320-280-20-3
11-112. WEAPON STATION TRAY AND BEARING SEALS MAINTENANCE

This task covers:
b. Installation
INITIAL SETUP:
All models except M996, M996A1, M997, ● Weapon station hatch removed (para. 11-42).
M997A1, M997A2, M998, M998A1, M1035, ● Hinge pivot bracket and gunner’s sling removed
M1035A1, M1035A2, M1037, M1038, (para. 11-52).

M1038A1, M1042, M1097, M1097A1, ● Gunner’s sling hook removed (para. 11-53).
M1097A2 ● Weapon station backrest pads removed

(para. 11-54).
Tools . Weapon station hatch latch removed (para. 11-50).
● Weapon station hatch tube removed (para. 11-51).
● Turret lock removed (para. 11-56).
M966, M966A1, M1036, M1045, M1045A1, M1045A2,
Materials/Parts M1046, and M1046A1 Only:
Adhesive (Appendix C, Item 3) ● TOW mount pedestal removed (para. 11-57).
Three locknuts (Appendix G, Item 76) ● TOW mount pedestal cover removed (para. 11-58).
Seal (Appendix G, Item 224) ● Weapon station inclinometer removed
(para. 11-60).
Personnel Required ● TOW MGS pan removed (para. 11-59).
One mechanic M1025, M1025A1, M1025A2, M1026, M1026A1,
One assistant M1043, M1043A1, M1043A2, M1044, and M1044A1
Manual References only
● Armament cover and seal removed (para. 11-62).
TM 9-2320-280-10 ● Armament mount panel removed (para. 11-61).
TM 9-2320-280-24P
M1043, M1043A1, M1043A2, M1044, and M1044A1
only
● Traversing bar removed (para. 12-161).
NOTE
Note location of attaching hardware for installation.
1. Remove three locknuts (7), washers (3), capscrews (2), washers (3), and weapon station
tray (1) from bearing (5), Discard locknuts (7).
NOTE
s The upper and lower turret bearing seals are basically the same.
Steps 2 and 3 apply to the lower bearing seal.
● Replace turret bearing seals that are damaged, separated, or
peeled out.
2. Remove eighteen capscrews (10), washers (11), and three turret lockring sections (9) from support
assembly (8).
3. Remove turret bearing seal (12) from support assembly (8) and remove remains of adhesive from
grooves in support assembly (8).
11-154
TM 9-2320-280-20-3
11-112. WEAPON STATION TRAY AND BEARING SEALS MAINTENANCE (Cont’d)

b. Installation
NOTE
● Perform steps 1 and 2 only if installing new turret bearing seals.
. New seal broad side fits into groove.

1. Apply adhesive to grooves in support assembly (8) and install turret bearing seal (12) into support
assembly (8).
2. Install three turret lockring sections (9) on support assembly (8) with eighteen washers (11) and
capscrews (10). Tighten capscrews (10) to 37 lb-ft (50 N-m).
3. Install weapon station tray (1) on bearing (5).
4. Ensure all mounting hardware capscrew holes (4) in weapon station tray (1) are aligned with
mounting hardware capscrew holes (6) in bearing (5).
5. Install weapon station tray (1) on bearing (5) with three washers (3), capscrews (2), washers (3),
and locknuts (7). Tighten locknuts (7) to 37 lb-ft (50 N-m).
11-155
TM 9-2320-280-20-3
11-112. WEAPON STATION TRAY AND BEARING SEALS MAINTENANCE (Cont’d)

c. Adjustment
NOTE
● Do not adjust weapon station tray if loose or damaged.
. Weapon station tray needs adjustment if it binds, sticks, or does not
rotate freely.
1. Loosen capscrew (6) securing support ring (1) to “C” pillar support bracket (7).
2. Check the gap between “C” pillar support bracket (7) and support ring (1).
NOTE
● If gap is the thickness of a slotted washer or greater, proceed to step 4.
● If no gap exists, proceed to step 3.
3. Remove one slotted washer (8) at a time, as required, and rotate weapon station tray (9) to check for
binding. If there is no improvement, proceed to step 5.
4. Add one slotted washer (8) at a time, as required, and rotate weapon station tray (9) to check for
binding. If there is no improvement, proceed to step 5.
5. Loosen eight capscrews (3) securing two clevises (5) to windshield (2). Rotate weapon station tray (9)
to check for binding.
6. If weapon station tray (9) rotation has improved, position adjustment slots (4) in clevises (5) where
weapon station tray (9) operated freely and tighten eight capscrews (3) and capscrew (6).
NOTE
If weapon station tray rotation has not improved after adjustment
procedures, remove turret bearing assembly.
7. Install primary weapon system and check operation of weapon station tray (10). Refer to TM 9-2320-
280-10.
11-156
TM 9-2320-280-20-3
1 1 - 1 1 2 . WEAPON STATION TRAY AND BEARING SEALS MAINTENANCE (Cont'd)
FOLLOW-ON TASKS: • Install weapon station hatch tube (para. 11-51).

• Install weapon station hatch latch (para. 11-50).
• Install weapon station backrest pads (para. 11-54).
• Install gunner’s sling hook (para. 11-53).
• Install hinge pivot bracket and gunner's sling (para. 11-52).
• Install weapon station hatch (para. 11-42).
• Install turret lock (para. 11-56).
• Check weapon station for proper operation (TM 9-2320-280-10).
M966, M966A1, M1036, M1045, M1045A1, M1045A2, M1046, M1046A1, and M1121
Only:
• Install TOW mount pedestal (para. 11-57).
• Install TOW mount pedestal cover (para. 11-58).
• Install TOW MGS pan (para. 11-59).
• Install weapon station inclinometer (para. 11-60).
M1025, M1025A1, M1025A2, M1026, M1026A1, M1043, M1043A1, M1043A2,
M1044, and M1044A1 Only:
• Install armament cover and seal (para. 11-62).
• Install armament mount panel (para. 11-61).
M1043, M1043A1, M1043A2, M1044, and M1044A1 Only:
• Install traversing bar (para. 12-161).
Change 1 11-156.1
TM-9-2320-280-20-3
1 1 - 1 1 2 . 1 . TURRET CLEANING
This task covers:

a. Turret Modification b. Cleaning
INITIAL SETUP:
All models except M996, M996A1, M997, Hose (Appendix D, Fig. D-119)
M997A1, M997A2, M998, M998A1, M1035, Fixture (Appendix D, Fig. D-117)
M1035A1, M1035A2, M1037, M1038, Bushing (Appendix D, Fig. D-118)
M1038A1, M1042, M1097, M1097A1,
Manual References
M1097A2, M1123
TM 9-2320-280-24P
Tools
NOT E
If not previously accomplished, perform task a. to allow use of hose
to clean turret.
a. Turret Modification
NOTE
The following optional procedure will aid in turret cleaning. Have
your commander’s concurrence before performing any modification
to the vehicle.
1. Locate and mark the position to drill hole (2) in inner bearing (1).
2. Remove weapon station tray and seal (para. 11-112).
3. Secure fixture (3) to inner bearing (1) with centerline of hole (4) aligned with mark on inner bearing (1).
4. Position 0.339-in. drill bit (5) (letter R drill bit) four inches from drill chuck jaws (6).
11-156.2 Change 1
TM 9-2320-280-20-3
1 1 - 1 1 2 . 1 . TURRET CLEANING (Cont'd)
DRILL 0.339-IN. (8.611 mm)

DIAMETER HOLE
THREAD HOLE 0.125-27 NPT
(17.27 mm)
(127 mm)
Change 1 11-156.3
TM 9-2320-280-20-3
5. Using fixture (2), drill 0.339-in. (8.611mm) diameter hole (3) in inner bearing (1).
6. Remove fixture (2) from inner bearing (1).
CAUTION
Ensure bearings are spread apart where drill bit will come
through inner bearing, or drill bit may damage bearing
7. Using hole drilled in step 5, drill 0.234-in. (5.944 mm) diameter hole (4) through inner bearing (1) only.
NOTE
After threading inner bearing hole, clean metal shavings
8. Using 0.125-27 NPT standard tap, thread hole (5).
DRILL 0.339-IN. (8.611 mm)

DIAMETER HOLE
DRILL 0.234-IN. (5.944 mm)

DIAMETER HOLE
THREAD HOLE 0.125-27 NPT
11-156.4 Change 1
TM 9-2320-280-20-3
9. Remove tapered end (6) on 0.125-27 NPT standard tap (7).

10. Using modified 0.125-27 NPT tap, finish threading hole (5).
11. Install weapon station tray and seal (para. 11-112).
AFTER
REMOVE
Change 1 11-156.5
TM 9-2320-280-20-3
b. Cleaning
1. Install hose (4) in hole (2) on inner bearing (1).

2. Connect low-pressure water hose (5) to hose (4).
3. Turn water on and rotate weapon station tray (3) several full rotations.
NOT E
Allow water to force out any dirt or grit within turret bearing.
4. Turn water off when cleaning is completed.
5. Disconnect low-pressure water hose (5) from hose (4).
NOT E
Hose assembly may either be stowed in place on weapon station
tray or removed.
6. Remove hose (4) from hole (2) on inner bearing (1).
11-156.6 Change 1
TM 9-2320-280-20-3
Change 1 11-157
TM-9-2320-280-20-3
1 1 - 1 1 3 . TURRET BEARING MAINTENANCE

This task covers:
b. Cleaning and Inspection
INITIAL SETUP:
All vehicles except: M996, M996A1, M997, One mechanic
M1035A1, M1035A2, M1037, M1038,
M1097A2, M1123 TM 9-2320-280-24P
General mechanic’s tool kit: Weapon station tray and bearing seals removed
Drycleaning solvent (Appendix C, Item 18) • Drycleaning solvent is flammable and will not be
Sealant (Appendix C, Item 38) used near an open flame. A fire extinguisher will
Detergent (Appendix C, Item 17) be kept nearby when the solvent is used. Use only
Two turret bearing seals in well-ventilated places.
(Appendix D, Fig. D-90) • Compressed air used for cleaning purposes will
Twelve locknuts (Appendix G, Item 78) not exceed 30 psi (207 kPa). Use only with
Turret seal (Appendix G, Item 227) effective chip guarding and personal protective
equipment (goggles/shield, gloves, etc.).
WARNING
Drycleaning solvent is flammable and will not be used near an open
flame. A fire extinguisher will be kept nearby when the solvent is
used. Use only in well-ventilated places. Failure to do this will
result in injury to personnel and/or damage to equipment.
NOT E
Drycleaning solvent may be used to assist in loosening the sealant
during removal.
a. Removal
1. Remove twelve locknuts (4), washers (5), and capscrews (2) from roof retainers (1), bearing assembly
(3), and support ring (6). Discard locknuts (4).
2. Remove twelve roof retainers (1) and bearing assembly (3) from support ring (6).
11-158 Change 1
TM 9-2320-280-20-3
1 1 - 1 1 3 . TURRET BEARING MAINTENANCE (Cont'd)
b. Cleaning and Inspection
1. Remove two seals (7) from grooves (8) in bearing assembly (3). Discard seals (7).
2. Remove old sealant from grooves (8) and surface of races (9) on bearing assembly (3).
3. Using high pressure water or steam directed between races (9), clean ball bearings (10) in bearing
assembly (3) with mild detergent.
WARNING
Compressed air used for cleaning purposes will not exceed 30 psi
(207 kPa). Use only with effective chip guarding and personal
protective equipment (goggles/shield, gloves, etc.).
4. Using compressed air, blow out moisture from ball bearings (10) in bearing assembly (3).
5. Place and rotate bearing assembly (3) on a flat surface, and ensure it rotates freely with a maximum
of 6 lb pull on the outer race (9).
6. If bearing assembly (3) does not rotate freely, send bearing assembly (3) to direct support maintenance.
7. If bearing assembly (3) rotates freely, proceed to step 8.
8. Cut an 11-foot piece of seal (7).
NOTE
• Stretch seal during installation to ensure seal is fully installed
in groove.
• The broad side of new seal fits into the groove.
• Ensure sealant is not used on ball bearings or races.
9. Place bearing assembly (3) on a flat surface, apply sealant into groove (8), and install seal (7).
10. Apply sealant to ends of seal (7) on bearing assembly (3).
NOTE
Allow to dry approximately 15 minutes before handling bearing assembly.
11. Turn bearing assembly (3) over, apply sealant into groove (8), and install second seal (7).
12. Apply sealant to ends of seal (7) on bearing assembly (3).
NOTE
Allow to dry one hour before installation.
Change 1 11-159
TM 9-2320-280-20-3
1 1 - 1 1 3 . TURRET BEARING MAINTENANCE (Cont'd)
c. Installation
1. Install bearing assembly (3) on support ring (9).

NOT E
Step 2 is to prevent roof leaks.
2. Using sealant, fill front and rear roof seams (6) and (4) (where left and right roof halves join together
and overlap).
3. Secure bearing assembly (3) to support ring (9) with twelve roof retainers (1), capscrews (2), washers (8),
4. Inside vehicle, apply sealant along area where support ring (9) and roof (5) meet.
FOLLOW-ON TASK: Install weapon station tray and bearing seals (para. 11-112).
11-160 Change 1
TM 9-2320-280-20-3
Section Il. S250 SHELTER CARRIER BODY MAINTENANCE
11-114. S250 SHELTER CARRIER BODY MAINTENANCE TASK SUMMARY
TASK PAGE
PROCEDURES
PARA. NO.
11-115. Shelter Support Reinforcement Replacement 11-162

11-116. Shelter Mounting Bracket Replacement 11-163
11-117. Shelter Carrier Tailgate Replacement 11-164
11-118. Shelter Carrier Tailgate Bracket 11-165
Replacement
11-119. Shelter Carrier Tailgate Chain Maintenance 11-166
11-120. Shelter Replacement 11-168
11-121. Shelter Support Assembly Replacement 11-170
11-122. Cab Enclosure Panel Replacement 11-172
11-161
TM 9-2320-280-20-3
11-115. SHELTER SUPPORT REINFORCEMENT REPLACEMENT I

This task covers:
INITIAL SETUP:
M1037, M1042, M1097, M1097A1, M1097A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
Materials/Parts
Two capscrews (Appendix G, Item 11)
NOTE
It maybe necessary to detach cab rear panel straps and
turnbuttons and roll cab rear panel upward to gain access to front
support reinforcements.
Remove two capscrews (7), lockwashers (6), washers (5), reinforcement (4), and shims (3) (if installed)
from mounting bracket (2). Discard capscrews (7) and lockwashers (6).
b. Installation
NOTE
Ensure correct positioning of shims, if installed, upon installation
of capscrews.
Install shims (3) (if installed) and reinforcement (4) on support assembly (1) and mounting bracket (2)
with two capscrews (7), lockwashers (6), and washers (5). Tighten capscrews (7) to 90 lb-ft (122 N=m).
11-162
TM 9-2320-280-20-3
11-116. SHELTER MOUNTING BRACKET REPLACEMENT

This task covers:
INITIAL SETUP:
M1037, M1042, M1097, M1097A1, M1097A2 TM 9-2320-280-24P
General mechanic’s tool kit: Shelter removed (para. 11-120).
Materials/Parts
Capscrew (Appendix G, Item 8)
NOTE
The procedure for replacement of all four mounting brackets is
basically the same. This procedure covers the left rear mounting
bracket.
Remove capscrew (5), lockwasher (4), washer (3), and mounting bracket (1) from shelter (2). Discard
capscrew (5) and lockwasher (4).
I b. Installation
Install mounting bracket (1) on shelter (2) with capscrew (5), lockwasher (4), and washer (3). Do not
tighten capscrew (5) until shelter (2) is installed.
(para. 11-120).
11-163
TM 2320-280-20-3
11-117. SHELTER CARRIER TAlLGATE REPLACEMENT

This task covers:
INITIAL SETUP:
M1037, M1042, M1097, M1097A1, M1097A2 One mechanic
One assistant
Tools
Materials/Parts
1. Remove four locknuts (9), washers (2), capscrews (1), and washers (2) from right and left tailgate
chain assemblies (10) and tailgate (8). Discard locknuts (9).
2. Remove six nuts (3), washers (4), capscrews (7), tailgate (8), and shims (6) from tailgate mounting
brackets (5).
b. Installation
1. Install shims (6) and tailgate (8) on tailgate mounting brackets (5) with six capscrews (7),
washers (4), and nuts (3). Tighten capscrews (7) to 26 lb-ft (35 N-m).
2. Install right and left tailgate chain assemblies (10) on tailgate (8) with four washers (2), cap-
screws (1), washers (2), and locknuts (9). Tighten capscrews (1) to 15 lb-ft (20 Nom).
11-164
TM 9-2320-280-20-3
11-118. SHELTER CARRIER TAlLGATE BRACKET REPLACEMENT

This task covers:
INITIAL SETUP
M1037, M1042, M1097, M1097A1, M1097A2 TM 9-2320-280-24P
General mechanic’s tool kit: Shelter carrier tailgate removed (para. 11-117).
Materials/Parts
NOTE
The procedure for replacement of right and left tailgate brackets is
basically the same. This procedure covers the right bracket.
a. Removal
1. Remove locknut (7), washer (6), capscrew (5), and washer (6) from tailgate bracket (8) and shelter
support assembly (3). Discard locknut (7).
2. Remove three locknuts (4), washers (2), capscrews (1), washers (2), and tailgate bracket (8) from
shelter support assembly (3). Discard locknuts (4).
b. Installation
1. Install tailgate bracket (8) on shelter support assembly (3) with three washers (2), capscrews (1),
2. Secure tailgate bracket (8) to shelter support assembly (3) with washer (6), capscrew (5), washer (6),
and locknut (7). Tighten locknut (7) to 65 lb-ft (88 N-m). Tighten capscrews (1) to 26 lb-ft (35 N-m).
FOLLOW-ON TASK: Install shelter carrier tailgate (para. 11-117).
11-165
TM 9-2320-280-20-3
11-119. SHELTER CARRIER TAlLGATE CHAIN MAINTENANCE

This task covers:
INITIAL SETUP:
M1037, M1042, M1097, M1097A1, M1097A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) Tailgate lowered (TM 9-2320-280-10),
Materials/Parts
NOTE
The procedure for replacement of right and left tailgate chain
assemblies is basically the same. This procedure covers the left
tailgate assembly.
1. Remove two locknuts (1), washers (2), capscrews (5), washers (2), reinforcing bracket (3), and
tailgate chain assembly (10) from body (11). Discard locknuts (1).
2. Remove two locknuts (9), washers (7), capscrews (6), washers (7), and tailgate chain assembly (10)
from tailgate (8). Discard locknuts (9).
b. Disassembly
1. Pry two chain links (12) apart and remove two chain mounting brackets (4) from chain (16).
2. Pry apart “S” hook (15) and remove “S” hook (15) from chain (14).
3. Pry apart chain link (13) and remove chain (14) from chain (16).
1. Install chain (14) on chain (16) with chain link (13).

2. Install “S” hook (15) on chain (14) and bend “S” hook (15) closed.
3. Install two chain mounting brackets (4) to chain (16) with two chain links (12).
1. Install tailgate chain assembly (10) and reinforcing bracket (3) on body (11) with two washers (2),
capscrews (5), washers (2), and locknuts (1). Tighten locknuts (1) to 15 lb-ft (20 Nom).
2. Install tailgate chain assembly (10) on tailgate (8) with two washers (7), capscrews (6), washers (7),
and locknuts (9). Tighten capscrews (6) to 15 lb-ft (20 N-m).
11-166
TM 9-2320-280-20-3
11-119. SHELTER CARRIER TAlLGATE CHAIN MAINTENANCE (Cont’d)
11-167
TM 9-2320-280-20-3
11-120. SHELTER REPLACEMENT

This task covers:
INITIAL SETUP:
M1037, M1042, M1097, M1097A1, M1097A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
Materials/Parts General Sadety Instructions
Eight capscrews (Appendix G, Item 11) Direct all personnel to stand clear during hoisting
Eight lockwashers (Appendix G, Item 128) operations.
Personnel Required
One mechanic
One assistant
WARNING
Direct all personnel to stand clear during hoisting operations. A
heavy, swinging load can be extremely dangerous.
1. Position chain hoist (2) over top of shelter (3).
2. Connect lifting chains (1) to chain hoist (2) and four comers of shelter (3).
NOTE
It maybe necessary to detach cab rear panel straps and
turnbuttons and roll cab rear panel upward to gain access to front
mounting brackets.
3. Remove eight capscrews (12), lockwashers (11), washers (10), and four reinforcements (9) from four
mounting brackets (6) and support assembly (4), and remove shims (7), if present. Discard
capscrews (12) and lockwashers (11).
4. Remove shelter (3) from support assembly (4) and vehicle body with chain hoist (2).
5. Remove mounting brackets (para. 11-116).
WARNING
Direct all personnel to stand clear during hoisting operations. A
heavy, swinging load can be extremely dangerous.
1. Install mounting brackets (pare. 11-116).
2. Install shelter (3) over support assembly (4) and gradually lower shelter (3) into Position on support
assembly (4).
NOTE
Shelter should be tightly fitted to front of support assembly and centered
from side to side. Shims should only be added to rear shelter mounts.
3. Position shelter (3) on support assembly (4) and front mounting points (5) and install front of shelter (3)
on front of support assembly (4) with two reinforcements (9), four washers (10), lockwashers (11), and
capscrews (12). Tighten capscrews (12) to 90 lb-ft (122 N.m) and capscrews (8) to 60 lb-ft (81 Nom).
11-168
TM 9-2320-280-20-3
11-120. SHELTER REPLACEMENT (Cont’d)

4. Install rear of shelter (3) on support assembly (4) with two reinforcements (9), four washers (10),
lockwashers (11), and capscrews (12). DO not tighten capscrews (12).
5. Add shims (7), as necessary, to rear shelter mounts to ensure snug fit between mounting brackets (6)
and support assembly (4). Tighten capscrews (12) to 90 lb-ft (122 N-m) and capscrews (8) to 60 lb-ft
(81 N.m).
6. Disconnect lifting
11-169
TM 9-2320-280-20-3
11-121. SHELTER SUPPORT ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
One assistant
Tools
TM 9-2320-280-24P
Materials/Parts
locknut (Appendix G, Item 58) Equipment Condition
Thirteen locknuts (Appendix G, Item 70) ● Shelter carrier tailgate brackets removed
Four locknuts (Appendix G, Item 79) (para. 11-118).
Three locknuts (Appendix G, Item 84) ● Cab enclosure panels removed (para. 11-122).
● Fuel filler housing removed (para. 10-2).
● Rear soft top curtain rolled up (TM 9-2320-280-10).
● Shelter removed (pars. 11-120).
a. Removal
1. Remove two locknuts (24), washers (2), capscrews (4), washers (5), and spacers (6) from support
assembly (27) and cargo floor (22). Discard locknuts (24)
2. Remove six locknuts (24), washers (2), reinforcement plates (23) and (25), six capscrews (3),
washers (2), and spacers (1) from support assembly (27) and “B” beam (26). Discard locknuts (24).
3. Remove two locknuts (21), washers (7), capscrews (9), and washers (10) from support
assembly (27) and cargo floor (22). Discard locknuts (21).
4. Remove locknut (34), washer (33), capscrew (29), washer (30), clamp (32), and fuel filler spout (28)
from body (31) and pull fuel filler spout (28) away for access to locknut (21). Discard locknut (34).
5. Remove two locknuts (21), washers (7), capscrews (8), and washers (7) from support assembly (27)
and cargo floor (22). Discard locknuts (21).
6. Remove four locknuts (19), washers (14), capscrews (13), and washers (14) from support assembly
and cargo floor (22). Discard locknuts (19).
7. Remove three locknuts (20), washers (15), capscrews (16), and washers (15) from support
assembly (27) and “D” beam (17). Discard locknuts (20).
8. Remove locknut (18), washer (12), capscrew (11), washer (12), and support assembly (27)
from cargo floor (22) and “D” beam (17). Discard locknut (18).
1. Install support assembly (27) on cargo floor (22) and “D” beam (17) with washer (12), capscrew (11),
2. Secure support assembly (27) to “D” beam (17) with three washers (15), capscrews (16),
3. Secure support assembly (27) to cargo floor (22) with four washers (14), capscrews (13),
4. Secure support assembly (27) to cargo floor (22) with two washers (7), capscrews (8), washers (7),
and locknuts (21).
5. Install support assembly (27) on “B” beam (26) with six spacers (1), washers (2), capscrews (3), two
reinforcement plates (23) and (25), six washers (2), and locknuts (24).
11-170
TM 9-2320-280-20-3
11-121. SHELTER SUPPORT ASSEMBLY REPLACEMENT (Cont’d)

6. Secure support assembly (27) to cargo floor (22) with two spacers (6), washers (5), capscrews (4),
7. Secure support assembly (27) to cargo floor (22) with two washers (10), capscrews (9), washers (7),
and locknuts (21).
8. Tighten four locknuts (19) to 26 lb-ft (35 N.m).
9. Tighten capscrews (3), (4), (8), (9), (11), and (16) to 65 lb-ft (88 N.m).
10. Install fuel filler spout (28) and clamp (32) on body (31) with washer (30), capscrew (29), washer (33),
and locknut (34).
FOLLOW-ON TASKS: ● Install cab enclosure panels (para. 11-122).

● Install shelter carrier tailgate brackets (para. 11-118).
● Install fuel filler housing (para. 10-2).
● Roll down rear soft top curtain (TM 9-2320-280-10).
. Install shelter (para. 11-120).
11-171
TM 9-2320-280-20-3
I 11-122. CAB ENCLOSURE PANEL REPLACEMENT I

This task covers:
lNITIAL SETUP:
One assistant
Tools
Three lockwashers (Appendix G, Item 109) Fixed rear door removed (para. 10-14).
a. Removal
1. Remove three nuts (5), lockwashers (4), and capscrews (7) from panel (1) and footwell (6). Discard
lockwashers (4).
2. Remove three screws (2) and panel (1) from “B” beam (3).
1. Install panel (1) on “B” beam (3) with three screws (2).
2. Install panel (1) on footwell (6) with three capscrews (7), lockwashers (4), and nuts (5). Tighten
nuts (5) to 15-20 lb-in. (2 Nom).
FOLLOW-ON TASK: Install fixed rear door (para. 10-14).
11-172
TM 9-2320-280-20-3
Section III. AMBULANCE BODY MAINTENANCE
1 1 - 1 2 3 . AMBULANCE BODY MAINTENANCE TASK SUMMARY
TASK PAGE
PROCEDURES
PARA. NO.
11-124. Soft Top Ambulance Litter Assembly Maintenance 11-176

11-125. Rear Door Maintenance 11-183
11-126. Rear Door Hinge Replacement 11-185
11-127. Rear Door Handles Replacement 11-186
11-128. Rear Door Latch Assembly and Guide Replacement 11-187
11-129. Rear Door Seal Protector Replacement 11-188
11-130. Rear Door Seals Replacement 11-189
11-131. Rear Door Latch Rod Striker Guides and 11-190
Brackets Maintenance
11-132. Rear Door Holder Assembly Replacement 11-192
11-133. Rear Steps Hinge Replacement 11-193
11-134. Rear Steps Striker and Bracket Maintenance 11-194
11-135. Rear Steps Latch Assembly Replacement 11-196
11-136. Rear Steps Retaining Cable Maintenance 11-198
11-137. Rear Steps Retractor Replacement 11-200
11-138. Rear Steps Maintenance 11-202
11-139. Upper Litter Rack Striker Replacement 11-206
11-140. Upper Litter Rack Replacement 11-207
11-141. Upper Litter Rack Striker Support Brackets 11-208
Replacement
11-142. Upper Litter Rack Latch Replacement 11-210
11-143. Upper Litter Rack Latch Bracket Replacement 11-211
11-144. Upper Litter Rack Support Bracket Replacement 11-212
11-145. Upper Litter Rack Strap and Ring Replacement 11-212.1
11-145.1. Litter Skid Tracks Edge Trim Replacement 11-212.2
11-146. Litter Skid Pad Replacement 11-214
11-147. Litter Handle Bumper Replacement 11-215
11-148. Spineboard Mounting Bracket Replacement 11-216
11-149. IV Bag Strap Replacement 11-218
11-150. IV Bag Hook Replacement 11-219
11-151. Stowage Box Turnbutton Replacement 11-220
11-152. Stowage Door Replacement 11-221
11-153. Ambulance Compartment Mat Replacement 11-222
11-154. Front Floorboard Replacement 11-223
11-155. Bulkhead Door Replacement 11-224
11-156. Bulkhead Door Latch Replacement 11-228
11-157. Attendant Seat Maintenance 11-232
11-158. Attendant Seat Guide Rail Replacement 11-234
11-159. Litter Stowage Door Replacement 11-235
11-160. Litter Stowage Tray Support and Strap Replacement 11-236
Change 1 11-173
TM 9-2320-280-20-3
1 1 - 1 2 3 . AMBULANCE BODY MAINTENANCE TASK SUMMARY (Cont'd)
TASK PAGE
PROCEDURES
PARA. NO.
11-161. Litter Rail Extension Replacement 11-238

11-162. NBC Compartment Door Replacement 11-240
(M997, M997A1, M997A2)
11-163. NBC Compartment Door Latch Replacement 11-241
11-164. NBC Heater Replacement 11-242
11-165. NBC Heater Brackets Replacement 11-243
11-166. NBC Air Line Piping Maintenance 11-244
11-167. NBC Gas Filter and Bracket Replacement 11-246
11-168. NBC Precleaner, Particulate Filter Assembly, 11-248
and Bracket Replacement
11-169. Intercom and Brackets Replacement 11-250
11-170. Rear Drip Rail Replacement 11-252
11-171. Radio Antenna Mount Replacement (M996, M996A1) 11-253
11-172. Radio Antenna Mount Replacement (M997, M997A1, M997A2) 11-254
11-173. Stowage Net Assembly Replacement 11-255
11-174. Red Cross Placard Retaining Clip Replacement 11-256
11-175. Red Cross Placard Replacement 11-257
11-176. Exterior Stowage Door Replacement 11-258
11-177. Attendant Seat Stowage Brackets Replacement 11-259
11-178. Rear Door Vent Assembly Replacement 11-260
11-179. Medical Stowage Cover and Latch Replacement 11-261
11-180. Edge Protector Replacement 11-262
11-180.1. Spreader Bar Tiedown Replacement 11-262.1
11-181. Ambulatory Patient Seat Maintenance 11-263
11-182. Ambulatory Patient Seat Rear Closeout Panel Replacement 11-265
11-183. NBC Door Maintenance (M996, M996A1) 11-266
11-184. Air Intake Compartment Panels Replacement 11-268
11-185. Air Intake Duct Door Replacement 11-269
11-186. Air Inlet/Outlet Grille Replacement 11-270
11-187. Front Cover Panel Replacement 11-271
11-188. Rear Cover Panel Replacement 11-272
11-189. Heater Exhaust Pipe Replacement (M997, M997A1, M997A2) 11-273
11-190. Heater Replacement (M997, M997A1, M997A2) 11-274
11-191. Heater Outlet Hose Replacement (M997, M997A1, M997A2) 11-276
11-192. Heater Fuel Filter Replacement 11-278
11-193. Heater Fuel Lines Replacement 11-280
11-194. Heater Fuel Pump Replacement 11-286
11-195. Heater Fuel System Bleeding 11-288
11-196. Floor Heat Duct Louver Replacement 11-290
11-197. Blower Motor Resistor Replacement 11-291
11-198. Blower Motor and Housing Maintenance 11-292
11-174 Change 1
TM 9-2320-280-20-3
11-123. AMBULANCE BODY MAINTENANCE TASK SUMMARY (Cont'd)
TASK PAGE
PROCEDURES
PARA. NO.
11-199. Duct Door Control Cables Maintenance 11-296

11-200. Evaporator Drain Tube Replacement 11-302
11-201. Condenser Cooling Fan Replacement 11-304
11-202. Compressor Belt Maintenance 11-306
11-203. Air-Conditioning Duct Louver Replacement 11-308
11-204. Heater Compartment Panel Replacement 11-309
(M996, M996A1)
11-205. Air Intake Filter Maintenance 11-310
11-206. Heater Outlet/Blower Fan Hose Replacement 11-312
(M996, M996A1)
11-207. Heater Exhaust Pipe Replacement (M996, M996A1) 11-313
11-208. Heater Mounting Bracket Assembly Replacement 11-314
(M996, M996A1)
11-209. Heater Replacement (M996, M996A1) 11-316
11-210. Blower Outlet Deflector Replacement 11-318
11-211. Heat/Air-Conditioning Duct Maintenance 11-319
11-212. Blower Assembly Replacement 11-321
11-213. Air Diverter Replacement (M996, M996A1) 11-323
11-214. Panel Insulation Replacement 11-324
11-215. Ambulance Spreader Bar Maintenance 11-325
11-175
TM 9-2320-280-20-3
11-124. SOFT TOP AMBULANCE LITTER ASSEMBLY MAINTENANCE

This task covers:
c. Inspection
INITIAL SETUP:
M1035, M1035A1, M1035A2 One mechanic
One assistant
Tools
TM 9-2320-280-24P
Special Tools
Torque adapter (Appendix B, Item 145) Equipment Condition
Tailgate lowered (TM 9-2320-280-10).
Materials/Parts
Ten locknuts (Appendix G, Item 58)
Twenty three locknuts (Appendix G, Item 106)
Eight lockwashers (Appendix G, Item 108)
Eight nut and lockwasher assemblies
NOTE
1. Remove two capscrews (22) and washers (21) from litter assembly (1), spacers (20), and cargo
floor (26).
2. Remove two locknuts (11), washers (12), capscrews (24), and washers (12) from litter
assembly (1), spacers (25), and cargo floor (26). Discard locknuts (11).
3. Remove four locknuts (13), washers (14), capscrews (19), washers (14), and shims (17) from litter
assembly (1) and wheelhouses (10). Discard locknuts (13).
4. Remove four locknuts (15), washers (16), capscrews (23), washers (16), and shims (18) from litter
assembly (1) and wheelhouses (10). Discard locknuts (15).
5. Remove two locknuts (9), washers (5), eapscrews (4), and washers (5) from spacers (6), litter
assembly (1), and cargo floor (26). Discard locknuts (9).
6. Remove two locknuts (8), washers (3), capscrews (2), and washers (3) from spacers (’7), litter
assembly (1), and cargo floor (26). Discard locknuts (8).
7. Remove litter assembly (1) from vehicle.
NOTE
Note position of spacers for installation.
8. Remove spacers (6), (7), (20), and (25) from cargo floor (26).
11-176
TM 9-2320-280-20-3
I 11-124. SOFT TOP AMBULANCE LITTER ASSEMBLY MAINTENANCE (Cont’d) I
11-177
TM 9-2320-280-20-3
11-124. SOFT TOP AMBULANCE LITTER ASSEMBLY MAINTENANCE (Cont’d) I

b. Disassembly
1. Remove six locknuts (17), washers (16), capscrews (25), and washers (16) from rear gusset
supports (20) and track assemblies (47). Discard locknuts (17).
2. Remove two locknuts (23), washers (19), capscrews (18), washers (19), and rear gusset supports (20)
from track assemblies (47). Discard locknuts (23).
3. Remove six locknuts (29), washers (27), capscrews (26), washers (27), and two wheelhouse gusset
supports (28) from track assemblies (47). Discard locknuts (29).
4. Remove two capscrews (14), lockwashers (13), and washers (12) from camrol stops (48) and track
assemblies (47). Unlatch and raise litter tray (4) to remove camrol stops (48) from track
assemblies (47). Discard lockwashers (13).
5. Remove litter tray (4) from track assemblies (47).
6. Remove two camrols (6) and washers (5) from litter tray (4).
7. Remove two nuts (43), lockwashers (42), washers (41), socket head shoulder bolts (1), and torsion
springs (2) from bumper support plates (40). Discard lockwashers (42).
8. Remove four screws (3) and two bumper support plates (40) from litter tray (4).
9. Remove two capscrews (30), lockwashers (31), washers (32), round support (11), and tube roller (10)
from track assemblies (47). Discard lockwashers (31).
10. Remove eight screws (44) and two shields (45) from tray assembly bumper (46) and track
assemblies (47).
11. Remove three locknuts (52), washers (51), capscrews (50), and stop (49) from track assembly (47)
(right side only). Discard locknuts (52).
12. Remove two capscrews (35), lockwashers (36), washers (37), and tray assembly bumper (46) from
track assemblies (47). Discard lockwashers (36).
13. Remove four locknuts (33), washers (34), capscrews (38), washers (34), and cross gusset bracket (39)
from track assemblies (47). Discard locknuts (33).
14. Remove eight rivets (8), four footman loops (9), and straps (7) from litter tray (4).
15. Remove eight nut and lockwasher assemblies (15), screws (22), four footman loops (21), and
straps (24) from track assemblies (47). Discard nut and lockwasher assemblies (15).
1. Inspect litter tray (4), track assemblies (47), rear gusset supports (20), and wheelhouse gusset
supports (28) for cracks, broken welds, and distortion. Replace any component if damaged.
2. Inspect tube roller (10), round support (11), and camrols (6) for warping and damage. Replace any
component if damaged.
3. Inspect torsion springs (2), socket head shoulder bolts (1), footman loops (9) and (21), and straps (24)
and (7) for damage. Replace any component if damaged.
11-178
TM 9-2320-280-20-3
11-124. SOFT TOP AMBULANCE LITTER ASSEMBLY MAINTENANCE (Cont’d)
11-179
TM 9-2320-280-20-3
d. Assembly
1. Install four straps (24) and footman loops (21) on two track assemblies (47) with eight screws (22)
and nut and lockwasher assemblies (15).
2. Install four straps (7) and footman loops (9) on litter tray (4) with eight rivets (8).
3. Install cross gusset bracket (39) on two track assemblies (47) with four washers (34), capscrews (38),
washers (34), and locknuts (33). Tighten capscrews (38) to 31 lb-ft (42 N-m).
4. Install tray assembly bumper (46) on two track assemblies (47) with two washers (37), lock-
washers (36), and capscrews (35). Tighten capscrews (35) to 31 lb-ft (42 N.m).
5. Install stop (49) on track assembly (47) (right side only) with three capscrews (50), washers (51), and
locknuts (52). Tighten capscrews (50) to 6 lb-ft (8 N.m).
6. Install two shields (45) on track assemblies (47) and tray assembly bumper (46) with eight
screws (44).
7. Install tube roller (10) on round support (11). Install round support (11) on two track assemblies (47)
with washers (32), lockwashers (31), and capscrews (30). Tighten capscrews (30) to 31 lb-ft (42 N=m).
8. Install two wheelhouse gusset supports (28) on track assemblies (47) with six washers (27),
capscrews (26), washers (27), and locknuts (29). Tighten locknuts (29) to 31 lb-ft (42 Nom).
9. Install two rear gusset supports (20) on track assemblies (47) with six washers (16), capscrews (25),
washers (16), and locknuts (17). Do not tighten locknuts (17).
10. Secure rear gusset supports (20) to track assemblies (47) with two washers (19), capscrews (18),
washers (19), and locknuts (23). Tighten capscrews (18) and locknuts (17) to 31 lb-ft (42 Nom).
11. Install two bumper support plates (40) on litter tray (4) with four screws (3).
CAUTION
Do not overtighten shoulder bolts.
12. Install two torsion springs (2) on socket head shoulder bolts (1) and install two socket head shoulder
bolts (1) on bumper support plates (40) with two washers (41), lockwashers (42), and nuts (43).
Tighten nuts (43) to end threads on socket head shoulder bolts (1).
13. Install two washers (5) and camrols (6) on litter tray (4).
14. Install litter tray (4) on track assembly (47) channels, and slide litter tray (4) toward tray assembly
bumper (46) until camrols (6) are past wheelhouse gusset supports (28).
15. Raise litter tray (4) to install two camrol stops (48) on track assemblies (47) and install camrol
stops (48) with two washers (12), lockwashers (13), and capscrews (14). Tighten capscrews (14) to
6 lb-ft (8 N.m).
11-180
TM 9-2320-280-20-3
( 11-124. SOFT TOP AMBULANCE LITTER ASSEMBLY MAINTENANCE (Cont’d)
11-181
TM 9-2320-280-20-3
e. Installation
1. Install litter assembly (1) in vehicle and install spacers (25), (20), (7), and (6) on mounting locations
between cargo floor (26) and litter assembly (1).
2. Secure litter assembly (1) to cargo floor (26) with two washers (3), capscrews (2), washers (3), and
3. Secure litter assembly (1) to cargo floor (26) with two washers (5), capscrews (4), washers (5), and
4. Secure litter assembly (1) to cargo floor (26) with two washers (12), capscrews (24), washers (12),
and locknuts (11). Do not tighten capscrews (24).
5. Install shims (18) between litter assembly (1) and side of wheelhouses (10) and install litter
assembly (1) on wheelhouses (10) with four washers (16), capscrews (23), washers (16), and
6. Install shims (17) between litter assembly (1) and top of wheelhouses (10) and install litter
assembly (1) on wheelhouses (10) with four washers (14), capscrews (19), washers (14), and
7. Secure litter assembly (1) to cargo floor (26) with two washers (21) and capscrews (22). Tighten
8. Tighten capscrews (19) and (23) to 6 lb-ft (8 N.m), Tighten capscrews (24) and (2) to 31 lb-ft
(42 Nom). Using torque adapter, tighten capscrews (4) to 75 lb-ft (102 N~m).
11-182
TM 9-2320-280-20-3
11-125. REAR DOOR MAINTENANCE

This task covers:
b. Installation
lNITIAL SETUP:
Applicable Models Peraonnel Required
M996, M996A1, M997, M997A1, M997A2 One mechanic
One assistant
Tools
TM 9-2320-280-24P
Materials/Parts
Six locknuts (Appendix G, Item 65) Equipment Condition
Rear doors opened (TM 9-2320-280-10).
Remove six locknuts (2), washers (3), capscrews (6), washers (3), door (5), and shims (4), if present, from
hinges (1). Discard locknuts (2).
b. Installation
Install door (5) and shims (4), if removed, on two hinges (1) with six washers (3), capscrews (6),
11-183
TM 9-2320-280-20-3
11-125. REAR DOOR MAINTENANCE (Cont’d)
1. Check adjustment and sealing of door (9) by inserting a sheet of paper between bottom edge of
door (9) and seal (3) on door frame (4), and closing both doors (9). Door seal (3) should offer
resistance when pulling out paper. If door seal (3) does not offer resistance, proceed to step 3.
2. Open door (9). Repeat step 1 for top edge and both side edges of door (9). If door seal (3) offers
resistance at all four sides of door (9), doors are adjusted correctly.
3. For vertical adjustment of door (9), loosen eight capscrews (12) securing hinges (1) to body (2). Slide
door (9) and hinges (1) up or down as required, hold door (9) in place, and tighten capscrews (12) to
15 lb-ft (20 Nom).
4. For outer edge of door (9) adjustment, loosen six locknuts (5) and capscrews (11) and remove or add
shims (6) as required between door (9) and hinge (1). Tighten locknuts (5) to 15 lb-ft (20 N-m).
5. If inner edges of doors (9) do not seal properly check for worn or damaged latch assembly rods (8),
left door seal (7), or latch rod catches (10). Replace latch rod catches (10) (para. 11-131), door seal (7)
(para. 11-130), or latch assembly (8) (para. 11-128) if damaged or worn.
6. Repeat steps 1 and 2 to ensure proper adjustment and sealing.
FOLLOW-ON TASKS: . Adjust latch rod catches (para. 11-131).

. Close rear doors (TM 9-2320-280-10).
11-184
TM 9-2320-280-20-3
11-126. REAR DOOR HINGE REPLACEMENT

This task covers:
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 TM 9-2320-280-24P
General mechanic’s tool kit: Rear door removed (para. 11-125).
Materials/Parts
Remove four capscrews (4), lockwashers (3), and hinge (2) from body (1). Discard lockwashers (3).
Install hinge (2) on body (1) with four lockwashers (3) and capscrews (4). Tighten capscrews (4)
to 15 lb-ft (20 N.m).
FOLLOW-ON TASK: Install rear door (para. 11-125).
11-185
TM 9-2320-280-20-3
11-127. REAR DOOR HANDLES REPLACEMENT I

This task covers:
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) Rear door opened (TM 9-2320-280-10).
Materials/Parts
Grease (Appendix C, Item 25)
a. Removal
1. Remove setscrew (9) and inner handle (1) from outer handle assembly (3) and door (5).
2. Remove four locknuts (8), washers (7), capscrews (4), and outer handle assembly (3) from latch
1. Apply a thin bead of sealing compound around inner plate of outer handle assembly (3).
2. Lubricate outer handle shaft (2) with grease.
3. Install outer handle assembly (3) on door (5) and latch assembly (6) with four capscrews (4),
4. Install inner handle (1) on outer handle assembly (3) with setscrew (9).
FOLLOW-ON TASK: Close rear door (TM 9-2320-280-10).
11-186
TM 9-2320-280-20-3
11-128. REAR DOOR LATCH ASSEMBLY AND GUIDE REPLACEMENT

This task covers:
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 TM 9-2320-280-24P
General mechanic’s tool kit Rear door handles removed (para. 11-127).
Materials/Parts
NOTE
For instructions in replacement of rivets, refer to para. 10-66.
1. Slide latch assembly (7) down until upper latch rod (8) is out of upper guide (2). Slide latch
assembly (7) up until lower latch rod (6) is out of lower guide (5).
2. Remove four rivets (1), latch guide (2), and shims (3), if present, from door (4).
I b. Installation
1. Install latch guide (2) and shims (3), if removed, on door (4) with four rivets (1).
2. Slide lower latch rod (6) into lower guide (5).
3. Insert upper latch rod (8) into upper guide (2) and slide latch assembly (7) up to mounting position.
FOLLOW-ON TASKS: ● Install rear door handles (para. 11-127).

. Adjust latch rod brackets (para. 11-131).
11-187
TM 9-2320-280-20-3
11-129. REAR DOOR SEAL PROTECTOR REPLACEMENT

This task covers:
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) Rear doors opened (TM 9-2320-280-10).
Materials/Parts
Five rivets (Appendix G, Item 184)
NOTE
a. Removal
Remove five rivets (2) and seal protector (3) from body (1).
Install seal protector (3) on body (1) with five rivets (2).
FOLLOW-ON TASK: Close rear doors (TM 9-2320-280-10).
11-188
TM 9-2320-280-20-3
11-130. REAR DOOR SEALS REPLACEMENT

This task covers:
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) ● Rear steps lowered (TM 9-2320-280-10).
● Rear door seal protector removed (para. 11-129).
Materials/Parts
NOTE
a. Removal
1. Pry seal (1) from body channel (2) and remove seal (1).
2. Remove two rivets (5), step seal (3), and retainer (4) from body (6).
3. Pry seal (8) from door (7) and remove plug (9) from seal (8).
b. Installation
1. Install plug (9) into seal (8) and install seal (8) on door (7).
2. Install step seal (3) and retainer (4) on body (6) with two rivets (5).
3. Install seal (1) by seating seal (1) into body channel (2).
FOLLOW-ON TASKS: “ Raise rear steps (TM 9-2320-280-10).

● Install rear door seal protector (para. 11-129).
● Adjust rear door (para. 11-125).
11-189
TM 9-2320-280-20-3
11-131. REAR DOOR LATCH ROD STRIKER GUIDES AND BRACKETS MAINTENANCE
This task covers:
a Striker Guide Removal d. Bracket Installation
b. Striker Guide Installation e. Striker Guide Adjustment
c. Bracket Removal
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) . Rear doors opened (TM 9-2320-280-10).
● Rear door blackout switch bracket removed
‘IWO locknuts (Appendix G, Item 58)
Three rivets (Appendix G, Item 178)
NOTE
Upper and lower striker guides and brackets are replaced basically
the same. This procedure covers the upper striker guide and bracket.
a. Striker Guide Removal

Remove two locknuts (7), washers (5), screws (4), washers (5), and striker guide (6) from bracket (2).
b. Striker Guide Installation

1. Install striker guide (6) on bracket (2) with two washers (5), screws (4), washers (5), and
locknuts (7). Do not tighten locknuts (7).
2. Proceed to Adjustment, e.2.
c. Bracket Removal
NOTE
1. Remove striker guide (step a. above).
2. Remove three rivets (3) and bracket (2) from body (1).
d. Bracket Installation
1. Install bracket (2) on body (1) with three rivets (3).
2. Install striker guide (step b. above).
e. Striker Guide Adjustment

1. Check all four striker guides (6) for proper clearance from latch rods (8). Clearance should be 1/8 in.
(3 mm) from end of latch rods (8) to surface of striker guides (6). If clearance of any striker guide (6)
is not within specifications, loosen two locknuts (7) from striker guide (6) and bracket (2).
2. Install striker guide (6) 1/8 in. (3 mm) from end of latch rod (8), hold in place, and tighten two
locknuts (7).
11-190
TM 9-2320-280-20-3
11-131. REAR DOOR LATCH ROD STRIKER GUIDES AND BRACKETS

MAINTENANCE (Cont’d)
FOLLOW-ON TASKS ● Install rear door blackout light switch bracket (para. 4-93).
● Close rear doors (TM 9-2320-280-10).
11-191
TM 9-2320-280-20-3
11-132. REAR DOOR HOLDER ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
Applicable Models Materals/Parts
M996, M996A1, M997, M997A1, M997A2 Two rivets (Appendix G, Item 185)
NOTE
● For instructions on replacement of rivets, refer to para. 10-66.
● Holder and guide must be replaced together both parts are
considered to be one assembly.
a. Removal
1. Remove two rivets (1) and guide (2) from door (3).
2. Remove screw (5) and holder (4) from body (6).
b. Installation
1. Install holder (4) on body (6) with screw (5).
2. Install guide (2) on door (3) with two rivets (1).
11-192
TM 9-2320-280-20-3
11-133. REAR STEPS HINGE REPLACEMENT

This task covers:
lNITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) Rear steps lowered (TM 9-2320-280-10).
Materals/Parts
1. Remove two locknuts (1), washers (2), capscrews (8), and washers (2) from hinge (5) and rear
steps (3). Discard locknuts (1).
2. Remove two capscrews (7), lockwashers (6), and hinge (5) from doorsill (4). Discard lockwashers.
b. Installation
1. Install hinge (5) on doorsill (4) with two capscrews (7) and lockwashers (6). Tighten capscrews (7) to
15 lb-ft (20 N.m).
2. Install hinge (5) on rear steps (3) with two washers (2), capscrews (8), washers (2), and locknuts (1).
FOLLOW-ON TASK: Raise rear steps (TM 9-2320-280-10).
11-193
TM 9-2320-280-20-3
11-134. REAR STEPS STRIKER AND BRACKET MAINTENANCE

This task covers:
a. Striker Removal d. Bracket Installation
b. Striker Installation e. Bracket Adjustment
c. Bracket Removal
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
Personnel Required
One mechanic
One assistant
a. Striker Removal
Remove striker (5) from bracket (4).
b. Striker Installation
Install striker (5) on bracket (4). Tighten striker (5) to 60 lb-ft (81 N.m).
c. Bracket Removal
Remove four capscrews (1), washers (2), and bracket (4) from body (3).
d. Bracket Installation
Install bracket (4) on body (3) with four capscrews (1) and washers (2). Do not tighten capscrews (1).
I e. Bracket Adjustment
1. Loosen four capscrews (1) from bracket (4) and body (3) on opposite bracket (4) replaced.
2. Raise rear steps (TM 9-2320-280-10) and ensure rear step latches are engaged on strikers (5).
3. Press rear step assembly firmly against body (3), hold in place, and tighten eight capscrews (1) on
two brackets (4) and body (3).
4. Lower rear steps (TM 9-2320-280-10). Tighten eight capscrews (1) to 6 lb-ft (8 N.m).
11-194
TM 9-2320-280-20-3
11-134. REAR STEPS STRIKER AND BRACKET MAINTENANCE (Cont’d) I
11-195
TM 9-2320-280-20-3
11-135. REAR STEPS LATCH ASSEMBLY MAINTENANCE

This task covers:
b. Installation
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 TM 9-2320-280-10
TM 9-2320-280-24P
Materials/Parts
NOTE
The procedure for replacing left and right latch assemblies is
basically the same. This procedure covers the right latch assembly.
a. Removal
1. Open split ring (7) from release cable (8) and latch (5).
2. Remove three locknuts (2), washers (3), capscrews (6), shim (4), and latch (5) from step frame (9).
b. Installation
1. Install shim (4) and latch (5) on step frame (9) with three capscrews (6), capscrews (3), and locknuts (2).
2. Install release cable (8) on latch (5) with split ring (7) and close split ring (7).
c. Adjustment
1. Loosen six locknuts (2) on latch (5) from step frame (9).
2. Raise rear steps (TM 9-2320-280-10) and ensure step latches (5) are engaged on strikers (1).
3. Press rear step assembly firmly against body (10), hold in place, and tighten six locknuts (2) on
latches (5) and step frame (9).
4. Lower rear steps (TM 9-2320-280-10) and tighten six locknuts (2) to 6 lb-ft (8 N*m).
5. If latches (5) do not center on strikers (1), add or remove shims (4).
11-196
TM 9-2320-280-20-3
11-135. REAR STEPS LATCH ASSEMBLY MAINTENANCE (Cont’d)
11-197
TM 9-2320-280-20-3
11-136. REAR STEPS RETAINING CABLE REPLACEMENT

This task covers:
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) ● Rear steps raised (TM 9-2320-280-10).
● Litter stowage door open (TM 9-2320-280-10).
Materials/Parts
Two locknuts (Appendix G, Item 106) General Safety Instructions
Rear steps must be raised before disconnecting
retractor lever from rear steps.
WARNING
Rear steps must be raised before disconnecting retractor lever
from rear steps. Failure to do this may cause injury to personnel
and damage to equipment.
NOTE
The procedure for replacing left and right retaining cables are
basically the same. This procedure covers the left retaining cable.
a. Removal
1. Remove locknut (6), washer (7), socket head screw (11), large washer (10), retaining table (3), and
retractor lever (9) from rear steps (8). Discard locknut (6).
2. Lower rear steps (TM 9-2320-280-10).
3. Remove locknut (1), washer (2), socket head screw (5), large washer (4), and retaining cable (3) from
body (12). Discard locknut (1).
b. Installation
1. Install retaining cable (3) on body (12) with large washer (4), socket head screw (5), washer (2), and
locknut (1). Tighten screw (5) to 37 lb-ft (50 N.m).
2. Raise rear steps (TM 9-2320-280-10).
3. Install retractor lever (9) and retaining cable (3) on rear steps (8) with large washer (10), socket
head screw (11), washer (7), and locknut (6). Tighten screw (11) to 31 lb-ft (42 Nom).
11-198
TM 9-2320-280-20-3
11-136. REAR STEPS RETAINING CABLE REPLACEMENT (Cont’d)
FOLLOW-ON TASK: Close litter stowage door (TM 9-2320-280-10).
11-199
TM 9-2320-280-20-3
11-137. REAR STEPS RETRACTOR REPLACEMENT

This task covers
INITIAL SETUP
M996, M996A1, M997, M997A1, M997A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) ● Rear steps raised (TM 9-2320-280-10).
M997, M997A1, and M997A2 only:
Materials/Parts ● Litter rail extension and litters removed from
Two locknuts (Appendix G, Item 106) stowage compartment (TM 9-2320-280-10).
General safety Instructions
Rear steps must be raised before disconnecting
retractor lever from rear steps.
WARNING
NOTE
The procedure for replacing rear steps retractor is similar for
M996, M996A1, M997, M997A1, and M997A2 ambulances.
a. Removal
1. Remove locknut (9), washer (11), socket head screw (1), large washer (2), retractor (8), and retaining
cable (3) from rear steps (10). Discard locknut (9).
3. Remove locknut (5), washer (6), capscrew (7), and retractor (8) from body (4). Discard locknut (5).
1. Install retractor (8) and retaining cable (3) on rear steps (10) with large washer (2), socket head
screw (1), washer (11), and locknut (9). Tighten screw (1) to 31 lb-ft (42 N=m).
3. Install retractor (8) on body (4) with capscrew (7), washer (6), and locknut (5). Tighten capscrew (7)
to 37 lb-ft (50 N.m).
11-200
TM 9-2320-280-20-3
11-137. REAR STEPS RETRACTOR REPLACEMENT (Cont’d)
FOLLOW-ON TASK: M997, M997A1, and M997A2 only

Install litter rail extension and litters in stowage compartment (TM 9-2320-280-10).
11-201
TM 9-2320-280-20-3
1 1 - 1 3 8 . REAR STEPS MAINTENANCE
This task covers:

INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 One mechanic
One assistant
Tools
TM 9-2320-280-24P
Materials/Parts
Adhesive (Appendix C, Item 3) Equipment Condition
Ten locknuts (Appendix G, Item 106) Rear steps raised (TM 9-2320-280-10).
Three cotter pins (Appendix G, Item 27.2) General Safety Instructions
One cotter pin (Appendix G, Item 27.1) Rear steps must be raised before disconnecting
Eight rivets (Appendix G, Item 186) retractor lever from rear steps.
________
________
WARNING

a. Removal
1. Remove two locknuts (5), washers (4), socket head screws (6), large washers (7), retaining cables (8),
and retractor lever (9) from rear step (3). Discard locknuts (5).
3. Remove rear steps latches (para. 11-135).
4. Remove four locknuts (1), washers (2), capscrews (11), washers (12), and rear step (3) from two
hinges (10). Discard locknuts (1).
11-202 Change 1
TM 9-2320-280-20-3
1 1 - 1 3 8 . REAR STEPS MAINTENANCE(Cont'd)
Change 1 11-202.1
TM 9-2320-280-20-3
1 1 - 1 3 8 . REAR STEPS MAINTENANCE (Cont'd)

NOT E
b. Disassembly
1. If damaged, remove two rubber seals (25), from sides of step frame (2).
2. Remove two seals (1) from edges of step frame (2).
3. Remove four screws (20) from seat (18) and lower tread plate (19), and pry up on seat (18) to remove
from tread plate (19). Clean remaining adhesive from lower tread plate (19).
4. Remove four locknuts (6), washers (5), capscrews (12), washers (5), and upper tread plate (21) from
step frame (2). Discard locknuts (6).
5. Remove four locknuts (14), washers (15), capscrews (17), washers (15), and lower tread plate (19)
from step frame (2) and two side plates (16). Discard locknuts (14).
NOTE
Cotter pins and washers may not be installed on all vehicles.
6. Remove cotter pin (23), washer (24), and knob (22) from side plate (16) and step frame (2). Discard
cotter pin (23).
7. Remove three cotter pins (7), washers (9), spring washers (10), clevis pins (13), and washers (9) from
two side plates (16) and step frame (2). Discard cotter pins (7).
8. Remove two rivets (3) and angle bracket (4) from step frame (2).
9. Remove six rivets (11) and two latch striker guide support brackets (8) from step frame (2).
c. Assembly
1. Install two latch striker guide support brackets (8) on step frame (2) with six rivets (11).
2. Install angle bracket (4) on step frame (2) with two rivets (3).
NOTE
Cotter pins and washers may not be installed on all vehicles.
3. Install two side plates (16) on step frame (2) with three washers (9), clevis pins (13), spring
washers (10), washers (9), and cotter pins (7).
4. Install side plate (16) on step frame (2) with knob (22), washer (24), and cotter pin (23).
5. Install upper tread plate (21) on step frame (2) with four washers (5), capscrews (12), washers (5),
6. Install lower tread plate (19) on side plates (16) with four washers (15), capscrews (17), washers (15),
7. Apply adhesive to back of seat (18). Install seat (18) on lower tread plate (19) with four screws (20).
8. Install two seals (1) on edges of step frame (2).
9. Install two rubber seals (25) on step frame (2) sides, if removed.
11-202.2 Change 1
TM 9-2320-280-20-3
Change 1 11-203
TM 9-2320-280-20-3
d. Installation
1. Install rear step (6) on two hinges (11) with four washers (5), capscrews (4), washers (8), and
locknuts (7). Raise steps and push in and down on steps while tightening capscrews (4).
2. Lower steps (TM 9-2320-280-10) and tighten locknuts (7) to 15 lb-ft (20 N•m).
3. Install and adjust rear step latches (para. 11-135).
5. Install retractor lever (3) and two retaining cables (2) on rear step (6) with two large washers (1),
socket-head screws (12), washers (9), and locknuts (10). Tighten screws (12) to 31 lb-ft (42 N•m).
11-204 Change 1
TM 9-2320-280-20-3
Change 1 11-205
TM 9-2320-280-20-3
11-139. UPPER LITTER RACK STRIKER REPLACEMENT

This task covers:
INITIAL SETUP:
M997, M997A1, M997A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) Upper litter rack placed in backrest position
(TM 9-2320-280-10).
a. Removal
Remove nut (1) and striker (2) from support (3).
Install striker (2) on support (3) with nut (1).
FOLLOW-ON TASK: Raise upper litter rack (TM 9-2320-280-10).
11-206
TM 9-2320-280-20-3
11-140. UPPER LITTER RACK REPLACEMENT

This task covers:
lNITlAL SETUP:
Applicable Models
M997, M997A1, M997A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) Upper litter rack placed in the backrest position
(TM 9-2320-280-10).
1. Remove two hitch pins (4), washers (5), retaining pins (2), four nylon washers (6), and upper litter
rack (1) from front and middle support brackets (3).
2. Release latch lock (8) and latch (9), and remove upper litter rack (1) from rear litter bracket (7) and
ambulance body (10).
1. Install upper litter rack (1) on ambulance body (10) and rear litter bracket (7) by locking latch (9)
and latch lock (8).
2. Install upper litter rack (1) on front and middle support brackets (3) with four nylon washers (6),
two retaining pins (2), washers (5), and hitch pins (4).
FOLLOW-ON TASK: Raise upper litter rack (TM 9-2320-280-10).
11-207
TM 9-2320-280-20-3
11-141. UPPER LITTER RACK STRIKER SUPPORT BRACKETS REPLACEMENT I

This task covers:
INITIAL SETUP:
M997, M997A1, M997A2 TM 9-2320-280-24P
General mechanic’s tool kit: Upper litter rack striker removed (para. 11-139)
Materials/Parts
Fourteen rivets (Appendix G, Item 184)
NOTE
1. Remove two rivets (8) from upper bracket (1) and roof (2).
2. Remove four rivets (5) and support (3) with brackets (1) and (6) from roof (2) and body (4).
3. Remove four rivets (9) and upper bracket (1) from support (3).
4. Remove four rivets (7) and lower bracket (6) from support (3).
b. Installation
1. Install lower bracket (6) on support (3) with four rivets (7).
2. Install upper bracket (1) on support (3) with four rivets (9).
3. Install upper bracket (1) and support (3) on roof (2) with two rivets (8).
4. Install lower bracket (6) and support (3) on body (4) with four rivets (5).
11-208
TM 9-2320-280-20-3
11-141. UPPER LITTER RACK STRIKER SUPPORT BRACKETS REPLACEMENT (Cont’d)
FOLLOW-ON TASK: Install upper litter rack striker (para. 11-139).
11-209
TM 9-2320-280-20-3
11-142. UPPER LITTER RACK LATCH MAINTENANCE

This task covers:
b. Intsallation
INITIAL SETUP:
M997, M997A1, M997A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
(TM 9-2320-280-10).
Materials/Parts
Remove three locknuts (4), capscrews (3), and latch (2) from litter rack (1). Discard locknuts (4).
b. Installation
Install latch (2) on litter rack (1) with three capscrews (3) and locknuts (4). Do not tighten capscrews (3).
c. Adjustment
1. Raise upper litter rack (1) (TM 9-2320-280-10), and ensure latch (2) is engaged on striker.
2. Hold litter rack (1) in place, and tighten three capscrews (3) to 10 lb-ft (14 Nom).
11-210
TM 9-2320-280-20-3
11-143. UPPER LITTER RACK LATCH BRACKET REPLACEMENT

This task covers:
INITIAL SETUP:
M997, M997A1, M997A2 TM 9-2320-280-24P
General mechanic’s tool kit Upper litter rack latch removed (para. 11-142).
Materials/Parts
NOTE
Remove four rivets (2) and bracket (1) from upper litter tray (3).
I b. Installation I
Install bracket (1) on upper litter tray (3) with four rivets (2).
FOLLOW-ON TASK: Install upper litter rack latch (para. 11-142).
11-211
TM 9-2320-280-20-3
11-144. UPPER LITTER RACK SUPPORT BRACKET REPLACEMENT

This task covers:
INITIAL SETUP:
M997, M997A1, M997A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
(TM 9-2320-280-10).
Materials/Parts
1. Remove hitch pin (5), washer (7), retaining pin (9), two nylon washers (6), and litter rack (8) from
support bracket (3).
2. Remove four capscrews (1), lockwashers (2), and support bracket (3) from body (4). Discard
lockwashers (2).
1. Install support bracket (3) on body (4) with four lockwashers (2) and capscrews (1). Tighten
capscrews (1) to 21 lb-ft (29 N~m).
2. Install litter rack (8) on support bracket (3) with two nylon washers (6), retaining pin (9), washer (7),
and hitch pin (5).
FOLLOW-ON TASK: Raise litter rack (TM 9-2320-280-10).
11-212
TM 9-2320-280-20-3
1 1 - 1 4 5 . UPPER LITTER RACK STRAP AND RING REPLACEMENT
This task covers:

INITIAL SETUP:
Applicable Models Materials/Parts (Cont'd)
M997, M997A1, M997A2 Two nut and lockwasher assemblies
Tools Two screws (Appendix G, Item 208)
automotive (Appendix B, Item 1) Manual References
TM 9-2320-280-24P
Materials/Parts
Two lockwashers (Appendix G, Item 109) Equipment Condition
Remove duct assembly (para. 4-103).
a. Removal
1. Remove two capscrews (4), lockwashers (3), and strap bracket (2) from roof (1). Discard
lockwashers (3).
2. Remove strap (5) from upper litter rack (6).
NOT E
• Some vehicles may have screws and nut and lockwasher
assemblies instead of rivets securing the ring assembly.
• For replacement of rivets, refer to para. 10-66.
3. Remove two rivets (8) and ring assembly (9) from upper litter rack (6).
b. Installation
1. Install ring assembly (9) on upper litter rack (6) with two screws (7) and nut and lockwasher
assemblies (10).
2. Install strap bracket (2) on roof (1) with two lockwashers (3) and capscrews (4). Tighten cap-
screws (4) to 10 lb-ft (14 N•m).
3. Connect strap (5) to upper litter rack (6) and tighten strap (5) to support upper litter rack (6).
FOLLOW-ON TASK: Install duct assembly (para. 4-103).
Change 1 11-212.1
TM 9-2320-280-20-3
1 1 - 1 4 5 . 1 . LITTER SKID TRACKS EDGE TRIM REPLACEMENT
This task covers:

INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2, Sealant, RTV (Appendix C, Item 3)
M1035, M1035A1, M1035A2
Manual References
Tools TM 9-2320-280-24P
NOTE
• No NSN is assigned to edge trim. It will need to be ordered
directly from the vendor (2L480). The part number (SD1276) is
for 500-feet (150 m) bulk edging. When ordering, specify how
many feet are needed.
• M996 and M996A1 vehicles require approximately 30 ft (19 m)
of trim; M997, M997A1, and M997A2 vehicles require
approximately 58 ft (18 m) of trim; and M1035, M1035A1, and
M1035A2 vehicles require approximately 59 ft (18 m) of trim.
a. Removal
1. Remove edge trim (2) from track edge (3).

2. Clean any remaining adhesive from track edge (3).
b. Installation
NOTE
• Edge trim must be cut to alow for interferences along tracks.
• Edge trim length must be shortened .50 in. (12.7 mm) at each
end to allow room for adhesive sealant application.
1. Measure length of skid track (1) and cut edge trim (2) to size.
NOTE
To prevent drying of adhesive sealant before edge trim can be
installed, install edge trim to only one track at a time.
2. Apply thin bead of adhesive sealant along full length of litter skid track edge (3).
NOTE
When installing edge trim sections on litter track edges, ensure
grip is positioned on outside of track edge to prevent edge trim
from loosening when litter is being used.
3. Install edge trim (2) on track edge (3).
4. Apply adhesive sealant to ends of edge trim (2) and smooth between track (1) and edge trim (2).
11-212.2 Change 1
TM 9-2320-280-20-3
1 1 - 1 4 5 . 1 . LITTER SKID TRACKS EDGE TRIM REPLACEMENT (Co n t ’ d )
GRIP
Change 1 11-213
TM 9-2320-280-20-3
11-146. LlTTER SKID PAD REPLACEMENT

This task covers:
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 TM 9-2320-280-24P
General mechanic’s tool kit: Litter strap removed (para. 11-160).
Materials/Parts
Nineteen rivets (Appendix G, Item 186)
NOTE
● Skid pads are removed and installed basically the same for both
M996, M996A1, M997, M997A1, and M997A2 ambulances. This
procedure covers lower skid pad replacement for M997, M997A1,
and M997A2 ambulances.
. For instructions on replacement of rivets, refer to para. 10-66.
Remove nineteen rivets (2) and skid pad (3) from body (1).
Install skid pad (3) on body (1) with nineteen rivets (2).
FOLLOW-ON TASK: Install litter strap (para. 11-160).
11-214
TM 9-2320-280-20-3
11-147. LITTER HANDLE BUMPER REPLACEMENT

This task covers:
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) Rear door opened (TM 9-2320-280-10).
Materials/Parts
NOTE
c The procedure for replacing litter handle bumpers are basically
the same for M996, M996A1, M997, M997A1, and M997A2
ambulances. This procedure covers the rear door litter handle
bumpers replacement for M997, M997A1, and M997A2
ambulances.
I a. Removal I
1. Remove two rivets (1) and upper bumper (2) from rear door (3).
2. Remove two screws (5) and lower bumper (4) from rear door (3).
1. Install lower bumper (4) on rear door (3) with two sinews (5).
2. Install upper bumper (2) on rear door (3) with two rivets (1).
FOLLOW-ON TASK: Close rear door (TM 9-2320-280-10).
11-215
TM 9-2320-280-20-3
11-148. SPINEBOARD MOUNTING BRACKET REPLACEMENT

This task covers:
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 Two lockwashers (Appendix G, Item 108)
Manual References
NOTE
The procedure for replacing the left and right spineboard mounting
brackets are basically the same for M996, M996A1, M997, M997A1,
and M997A2 ambulances. This procedure covers replacement of a
right spineboard bracket on M997, M997A1, and M997A2
ambulances.
1. Remove spineboard from stowage position.

2. Remove six screws (1), footman loops (3) and (6), and vertical strap assembly (4) from body (2).
3. Remove four screws (11), washers (10), washers (9), and two brackets (8) from body (2).
4. Remove two nuts (7), lockwashers (14), screws (13), footman loop (12), and horizontal strap assembly (5)
from bracket (8). Discard lockwashers (14).
1. Install horizontal strap assembly (5) and footman loop (12) on bracket (8) with two screws (13),
Iockwashers (14), and nuts (7).
2. Install two brackets (8) on body (2) with four screws (11), washers (10), and washers (9).
3. Install vertical strap (4), footman loop (6), and footman loop (3) on body (2) with six screws (1).
4. Install spineboard and adjust brackets (8) by loosening screws (11) and sliding brackets (8) so that
spineboard is held securely and tighten screws (11). Install and tighten strap assemblies (5) and (4)
on spineboard.
11-216
TM 9-2320-280-20-3
11-148. SPINEBOARD MOUNTING BRACKET REPLACEMENT (Cont’d)
11-217
TM 9-2320-280-20-3
11-149. IV BAG STRAP REPLACEMENT

This task covers:
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 TM 9-2320-280-24P
Tools
Remove screw (3) and strap (2) from body (1).
Install strap (2) on body (1) with screw (3).
11-218
TM 9-2320-280-20-3
11-150. IV BAG HOOK REPLACEMENT

This task covers:
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 TM 9-2320-280-24P
Tools
a. Removal
Remove eyebolt (1) from body (2) and remove hook (3) from eyebolt (1).
b. Installation
Install hook (3) on eyebolt (1) and install eyebolt (1) into body (2).
11-219
TM 9-2320-280-20-3
11-151. STOWAGE BOX TURNBUTTON REPLACEMENT

This task covers:
INITIAL SETUP:
M997, M997A1, M997A2 TM 9-2320-280-24P
Tools
a. Removal
1. Remove curtain eyelet (1) from turnbutton (2) on stowage box (3).
2. Remove turnbutton (2) from stowage box (3).
b. Installation
1. Install turnbutton (2) on stowage box (3).
2. Install curtain eyelet (1) on turnbutton (2) on stowage box (3).
11-220
TM 9-2320-280-20-3
11-152. STOWAGE DOOR REPLACEMENT

This task covers:
INITIAL SETUP:
M997, M997A1, M997A2 Twelve rivets (Appendix G, Item 187)
NOTE
● Upper and lower stowage doors are removed and installed
basically the same. This procedure covers the lower stowage
door.
a. Removal
1. Remove seal (4), if damaged, from door (8).

2. Remove three rivets (3) and door (8) from hinge (2).
3. Remove three rivets (1) and hinge (2) from bulkhead (6).
4. Remove two rivets (5) and hasp (7) from bulkhead (6).
5. Remove four rivets (10) and staple (9) from door (8).
1. Install hasp (7) on bulkhead (6) with two rivets (5).

2. Install staple (9) on door (8) with four rivets (10).
3. Install hinge (2) on bulkhead (6) with three rivets (1).
4. Install door (8) on hinge (2) with three rivets (3).
5. Install seal (4) on door (8), if removed.
11-221
TM 9-2320-280-20-3
11-153. AMBULANCE COMPARTMENT MAT REPLACEMENT

This task covers:
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
Materials/Parts
NOTE
1. Remove nine rivets (6) and front mat retainer (5) from mat (1) and floor (4).
2. Remove nine rivets (3), rear mat retainer (2), and floor mat (1) from floor (4).
1. Install floor mat (1) and front mat retainer (5) on floor (4) with nine rivets (6).
2. Install rear mat retainer (2) on floor (4) with nine rivets (3).
11-222
TM 9-2320-280-20-3
11-154. FRONT FLOORBOARD REPLACEMENT

This task covers:
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2, TM 9-2320-280-24P
M998, M998A1, M1038, M1038A1
Tools
NOTE
The procedure to remove and instill the front and rear floorboards
are basically the same. The following procedure is for the front
floorboard.
a. Removal
Remove four screws (2) and floorboard (1) from floor (3).
b. Installation
Install floorboard (1) on floor (3) with four screws (2).
11-223
TM 9-2320-280-20-3
11-155. BULKHEAD DOOR REPLACEMENT

This task covers:
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 Seventy-four rivets (Appendix G, Item 184)
Twenty rivets (Appendix G, Item 186)
Tools
NOTE
● M996, M996A1, M997, M997A1, and M997A2 bulkhead doors
are replaced basically the same, except for the following

Forty-eight rivets are used to mount M996 and M996A1
bulkhead doors to bulkhead.
Ten rivets are used to mount M996 and M996A1 door
retainer to door.
Bulkhead door striker placement is different for M996,
M996A1, M997, M997A1, and M997A2 ambulances.
. This procedure covers M997, M997A1, and M997A2 bulkhead
door replacement.
1. Starting at top of door opening (1), pry seal (2) from around door opening (1) and remove seal (2).
2. Pry seal (37) from right door retainer (36) and remove seal (37).
NOTE
Step 3 applies to M996 and M996A1 vehicles only.
3. Remove two screws (34) from strap assembly (35) and right door (29).
4. Remove thirty-four rivets (11), two hinges (12), and doors (4) and (29) from body (3).
5. Remove thirty-four rivets (11) and two hinges (12) from doors (4) and (29).
6. Remove two screws (8), doughnut washers (7), handle (5), and doughnut washers (6) from left door (4).
7. Remove eight rivets (10) and two strikers (9) from doors (4) and (29).
8. Remove fourteen rivets (33) and door retainer (36) from right door (29).
9. Remove four screws (22), washers (23), two rod guide cover plates (24), and plusnuts (25) from right
door (29).
10. Remove screw (28), washer (27), and blackout switch pin (26) from right door (29).
11. Remove setscrew (31), handle (32), and washer (30) from right door (29).
12. Remove four screws (39), washers (38), and handle cover plate (19) from right door (29).
13. Remove three nuts (21), washers (20), screws (16), washers (17), and handle (18) from cover
plate (19).
14. Remove four rivets (13) and two catch assemblies (14) from stowage shelves (15).
11-224
TM 9-2320-280-20-3
11-155. BULKHEAD DOOR REPLACEMENT (Cont’d)
11-225
TM 9-2320-280-20-3
1. Install handle (18) on handle cover plate (19) with three washers (17), screws (16), washers (20, and
nuts (21).
2. Install handle cover plate (19) on right door (29) with four washers (38) and screws (39).
3. Install washer (30) and handle (32) on right door (29) with setscrew (31).
4. Install blackout switch pin (26) on right door (29) with washer (27) and screw (28).
5. Install two plusnuts (25) and rod guide cover plates (24) on right door (29) with four washers (23)
and screws (22).
6. Install door retainer (36) on right door (29) with fourteen rivets (33).
7. Install two strikers (9) on doors (4) and (29) with eight rivets (10).
8. Install handle (5) and two doughnut washers (6) on left door (4) with two screws (8) and doughnut
washers (7).
9. Install two hinges (12) on doors (4) and (29) with thirty-four rivets (11).
NOTE
Step 10 applies to M996 and M996A1 vehicles only.
10. Install strap assembly (35) on right door (29) with two screws (34).
11. Install hinges (12) on body (3) with thirty-four rivets (11).
12. Install two catch assemblies (14) on stowage shelves (15) with four rivets (13).
13. Install seal (37) on right door retainer (36) by pushing into place.
14. Install seal (2) by starting at top of door opening (1) and pushing seal (2) into place around door
opening (1).
11-226
TM 9-2320-280-20-3
11-227
TM 9-2320-280-20-3
11-156. BULKHEAD DOOR LATCH REPLACEMENT

This task covers:
INITIAL SETUP:
Applicable Models MateriaWParts
M996, M996A1, M997, M997A1, M997A2 Twelve rivets (Appendix G, Item 184)
NOTE
● Perform step 1 for M996 and M996A1 vehicles.
1. Remove twelve rivets (3) and right bulkhead door (1) from hinge (2).
2. Remove four screws (9), washers (10), and two rod guide cover plates (8) from door (1).
3. Remove four nuts (7), washers (6), screws (4), washers (6), and two rod guides (5) from door (1).
11-228
TM 9-2320-280-20-3
11-156. BULKHEAD DOOR LATCH REPLACEMENT (Cont’d) I

4. Remove setscrew (11), handle (12), and washer (13) from door (1).
5. Remove four screws (16), washers (15), cover plate (14), and handle (17) from door (1).
6. Remove four nuts (23), washers (20), screws (19), and washers (20) from latch assembly (22) and
door (1).
7. Rotate latch assembly (22) to horizontal position and disconnect rods (21) and (24), then remove
latch assembly (22).
NOTE
Perform step 8 for M996 and M996A1 vehicles. Perform step 9
for M997, M997A1, and M997A2 vehicles.
8. Remove upper rod (21) through rod opening (18) at top of door (1), and lower rod (24) through rod
opening (26) at bottom of door (1).
9. Remove upper rod (21) and lower rod (24) through latch opening (25) in door (1),
11-229
TM 9-2320-280-20-3
I 11-156. BULKHEAD DOOR LATCH REPLACEMENT (Cont’d) I

b. Installation
NOTE
Perform step 1 for M996 and M996A1 vehicles. Perform step 2
for M997, M997A1, and M997A2 vehicles.
1. Install upper rod (5) through rod opening (2) at top of bulkhead door (1), and lower rod (8) through
rod opening (10) at bottom of door (1).
2. Install upper rod (5) and lower rod (8) through latch opening (9) in door (1).
3. Install latch assembly (6) through latch opening in door (1), rotate latch assembly (6) to a horizontal
position, and connect rods (5) and (8) to latch assembly (6).
4. Rotate latch assembly (6) to a vertical position and install two washers (4), screws (3), washers (4),
and nuts (7).
5. Install cover plate (14) and handle (17) on door (1) with four washers (15) and screws (16).
6. Install washer (13) and handle (12), on handle (17) with setscrew (11).
11-230
TM 9-2320-280-20-3
11-156. BULKHEAD DOOR LATCH REPLACEMENT (Cont’d)
7. Install two rod guides (19) on door (1) with four washers (20), screws (18), washers (20), and
nuts (21).
8. Install two rod guide cover plates (22) on door (1) with four washers (24) and screws (23).
NOTE
Perform step 9 for M996 and M996A1 vehicles.
9. Install door (1) on hinge (25) with twelve rivets (26).
11-231
TM 9-2320-280-20-3
11-157. ATTENDANT SEAT MAINTENANCE

This task covers:
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 Two cotter pins (Appendix G, Item 25)
Tools
NOTE
● The attendant seat assemblies are similar for M996, M996A1, M997,
M997A1, and M997A2 ambulances with the following exceptions:
— The M996 and M996A1 ambulance attendant seat must be removed
from forward ends of attendant seat rails.
— The M997, M997A1, and M997A2 ambulance attendant seat must
be removed from rearward ends of attendant seat rails.
Push seat latch (3) to release locking mechanism and slide seat (1) to end of seat rails (2). Remove
seat (1) from rails (2).
b. Disassembly
1. Remove two locknuts (7), capscrews (6), and seatbelt (4) from seat base (8). Discard locknuts (7).
2. Remove socket head screw (15), washer (16), washer (17), handle (18), and nylon washer (11) from
seat base (8).
3. Remove two cotter pins (12), washers (14), clevis pins (10), and handle (18) from latch rods (9).
4. Disconnect spring (13) from handle (18) and seat base (8) and remove spring (13).
5. Remove four screws (19) and cushion (5) from seat base (8).
1. Install cushion (5) on seat base (8) with four screws (19).
2. Install latch rods (9) on seat base (8).
3. Connect latch rods (9) to handle (18) with two clevis pins (10), washers (14), and cotter pins (12).
4. Install handle (18) and nylon washer (11) on seat base (8) with washer (17), washer (16), and socket
head screw (15).
5. Connect spring (13) to handle (18) and seat base (8).
6. Install seatbelt (4) on seat base (8) with two capscrews (6) and capscrew S (7). Tighten locknuts (7) to
60 lb-ft (81 N.m).
11-232
TM 9-2320-280-20-3
11-157. ATTENDANT SEAT MAINTENANCE (Cont’d)
NOTE
● The M996 and M996A1 ambulance attendant seat must be
installed at forward ends of attendant seat rails.
● The M997, M997A1, and M997A2 ambulance attendant seat
must be installed at rearward ends of attendant seat rails.
Install seat (1) on ends of seat rails (2) and slide seat (1) onto seat rails (2).
11-233
TM 9-2320-280-20-3
11-158. ATTENDANT SEAT GUIDE RAIL REPLACEMENT

This task Covers:
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 TM 9-2320-280-24P
.
Equipment Condition
Tools
General mechanic’s tool kit Attendant seat removed (para. 11-157).
Materials/Parts
NOTE
● The procedures for replacing the left and right attendant seat
guide rails are basically the same for M996, M996A1, M997,
M997A1, and M997A2 ambulances. This procedure covers
replacement of the left attendant seat guide rail on M997,
M997A1, and M997A2 ambulance.
● M996 and M996A1 have seventeen rivets securing guide rail.
Remove twenty rivets (1) and guide rail (2) from ambulance body (3).
b. Installation
Install guide rail (2) on ambulance body (3) with twenty rivets (1).
FOLLOW-ON TASK: Install attendant seat (para. 11-157).
11-234
TM 9-2320-280-20-3
11-159. LITTER STOWAGE DOOR REPLACEMENT

This task covers:
INITIAL SETUP
M996, M996A1, M997, M997A1, M997A2 Ten rivets (Appendix G, Item 188)
Tools
NOTE
1. Remove five rivets (6) and door (9) from hinge (8).
2. Remove two rivets (5) and latch (4) from door (9).
3. Remove five rivets (7) and hinge (8) from body (1)..
4. Remove two rivets (3) and catch (2) from body (1).
5. Remove seal (10), if damaged, from body (1).
I b. Installation
1. Install seal (10), if removed, on body (1).
2. Install catch (2) on body (1) with two rivets (3).
3. Install hinge (8) on body (1) with five rivets (7).
4. Install latch (4) on door (9) with two rivets (5).
5. Install door (9) on hinge (8) with five rivets (6).
11-235
TM 9-2320-280-20-3
11-160. LITTER STOWAGE TRAY SUPPORT AND STRAP REPLACEMENT

This task covers:
a. Leg Removal c. Straps Removal
b. Leg Installation d. Straps Installation
lNITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) Litter stowage door opened (TM 9-2320-280-10).
Materials/Parts
NOTE
Steps a. and b. apply to M997, M997A1, and M997A2 vehicles only.
1. Remove spring (5) from litter tray support (3) and litter tray (2).
NOTE
2. Remove four rivets (1), two brackets (4), and litter tray support (3) from litter tray (2).
b. Leg Installation
1. Install litter tray support (3) and two brackets (4) on litter tray (2) with four rivets (1).
2. Install spring (5) on litter tray (2) and support (3).
NOTE
Steps c. and d. apply to M996 and M996A1 vehicles only.
c. Straps Removal
Remove two screws (7), footman loop (9), and straps (8) from body (6).
NOTE
If rivnuts are damaged, refer to para. 10-66 for replacement.
d. Straps Installation
Install straps (8) and footman loop (9) on body (6) with two screws (7).
11-236
TM 9-2320-280-20-3
11-160. LITTER STOWAGE TRAY SUPPORT AND STRAP REPLACEMENT (Cont’d) I
(TM 9-2320-280-10).
11-237
TM 9-2320-280-20-3
11-161. LITTER RAIL EXTENSION REPLACEMENT

This task covers:
lNITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 TM 9-2321-280-10
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) Litter rail extension removed from stowage
compartment (TM 9-2320-280-10).
Materials/Parts
Twenty-two rivets Appendix G, Item 190)
NOTE
a. Disassembly
1. Remove two locknuts (18), washers (15), capscrews (14), washers (15), support feet (17), and tubes (16)
from support legs (12). Discard locknuts (18).
2. Remove four locknuts (21), washers (22), capscrews (24), washers (22), and strap assembly (23)
from two support legs (12). Discard locknuts (21).
NOTE
3. Remove four locknuts (20), washers (19), capscrews (26), washers (19), and hinge braces (25) from
support legs (12). Discard locknuts (20).
4. Remove four locknuts (30), washers (29), capscrews (27), and two hinges (28) from four hinge braces (25).
5. Remove two locknuts (10), washers (8), capscrews (7), washers (8), support legs (12), and tubes (9)
from rails (6). Discard locknuts (10).
6. Remove four rivets (13) and two leg stops (11) from support legs (12).
7. Remove eight rivets (1) from ends of two extension rail skids (2). Remove twenty-two rivets (3) and
two skids (2) from extension rails (6).
8. Remove eight rivets (5) and two hooks (4) from extension rails (6).
I b. Assembly
1. Install two hooks (4) and ends of skids (2) on extension rails (6) with eight rivets (5).
2. Install two skids (2) to extension rails (6) and secure to ends with eight rivets (1).
3. Install skids (2) on extension rails (6) with twenty-two rivets (3).
4. Install two leg stops (11) on support legs (12) with four rivets (13).
5. Install two support legs (12) and tubes (9) on rails (6) with two washers (8), capscrews (7),
6. Install four hinge braces (25) on two hinges (28) with four capscrews (27), washers (29), and locknuts (30).
7. Install four hinge braces (25) on two support legs (12) with four washers (19), capscrews (26),
8. Install strap assembly (23) on two support legs (12) with four washers (22), capscrews (24),
9. Install two support feet (17) and tubes (16) on support legs (12) with two washers (15), capscrews (14),
11-238
TM 9-2320-280-20-3
11-161. LlTTER RAIL EXTENSION REPLACMENT (Cont’d)
FOLLOW-ON TASK: Install litter rail extension in stowage compartment (TM 9-2320-280-10).
11-239
TM 9-2320-280-20-3
11-162. NBC COMPARTMENT DOOR REPLACEMENT (M997, M997A1 , M997A2)

This task covers:
INITIAL SETUP:
M997, M997A1, M997A2 Lockwasher (Appendix G, Item 119)
Tools
NOTE
a. Removal I
1. Remove nine rivets (3) and door (4) from hinge (2).
2. Remove nine rivets (1) and hinge (2) from body (5).
3. Remove nut (6), nut (7), lockwasher (8), retainer (9), and paddle lock (11) from door (4). Discard
lockwasher (8).
4. Remove jamnut (10) from paddle lock (11).
I b. Installation
1. Install jamnut (10) on paddle lock (11).
2. Install paddle lock (11) on door (4) with retainer (9), lockwasher (8), nut (7), and nut (6).
3. Install hinge (2) on body (5) with nine rivets (1).
4. Install door (4) on hinge (2) with nine rivets (3).
11-240
TM 9-2320-280-20-3
11-163. NBC COMPARTMENT DOOR LATCH REPLACEMENT

This task covers:
INITIAL SETUP:
M997, M997A1, M997A2 Four screw-assembled lockwashers
Tools
Remove four screw-assembled lockwashers (3) and latch (1) from ceiling (2). Discard screw-assembled
lockwashers (3).
Install latch (1) on ceiling (2) with four screw-assembled lockwashers (3).
11-241
TM 9-2320-280-20-3
I 11-164. NBC HEATER REPLACEMENT

This task covers:
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
NOTE
● The procedure for replacing NBC heaters in M996, M996A1,
M997, M997A1, and M997A2 ambulances is basically the same.
This procedure covers the driver’s NBC heater in the M997,
M997A1, and M997A2 ambulances.
● Prior to removal, tag all leads for installation.
a. Removal
1. Disconnect lead 786 (10)from heater (1).
2. Loosen clamp (6) on heater (1) and NBC pipe connector (5).
3. Remove four nuts (9), washers (8), capscrews (4), washers (3), heater (1), and ground lead (7) from
body (2).
1. Install heater (1) and ground lead (7) on body (2) with four washers (3), capscrews (4), washers (8),
and nuts (9).
2. Install NBC pipe connector (5) to heater (1) with clamp (6).
3. Install lead 786 (10) to heater (1).
FOLLOW-ON TASKS: ● Check operation of NBC heater (TM 9-2320-280-10).

11-242
TM 9-2320-280-20-3
11-165. NBC HEATER BRACKETS REPLACEMENT I

This task covers:
INITIAL SETUP:
M997, M997A1, M997A2 TM 9-2320-280-24P
General mechanic’s tool kit: NBC heaters removed (para. 11-164).
NOTE
Left and right NBC heater brackets are replaced basically the
same. This procedure covers replacement of left heater brackets.
1. Remove NBC piping (6) from two clamps (7).

2. Remove four capscrews (9), washers (8), and NBC heater mounting bracket (5) from bulkhead
brackets (1).
3. Remove four capscrews (4), washers (3), and two bulkhead brackets (1) from bulkhead (2).
I b. Installation
1. Install two bulkhead brackets (1) on bulkhead (2) with four washers (3) and capscrews (4).
2. Install NBC heater mounting bracket (5) on two bulkhead brackets (1) with four washers (8) and
capscrews (9).
3. Install NBC piping (6) in two clamps (7).
FOLLOW-ON TASK: Install NBC heaters (para. 11-164).
11-243
TM 9-2320-280-20-3
I 11-166. NBC AIR LINE PIPING MAINTENANCE

This task covers:
b. Air Line Piping Fabrication
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 Adhesive (Appendix C, Item 6)
NOTE
● Replacement and repair for NBC air lines in M996, M996A1,
M997, M997A1, and M997A2 ambulances are basically the
same. This procedure gives general guidelines for repair or
replacement of PVC pipe.
c The PVC pipe used in ambulance NBC air lines is made up of
tees, elbows, connecters, and miscellaneous lengths of straight
pipe. All of these are connected and sealed with PVC adhesive.
Before beginning a repair or replacement procedure, ensure that
you have all necessary pipe, connectors, and PVC adhesive.
Remove section of damaged pipe (6). Damaged pipe section (6) will have to be cut from system because
pipe joints cannot be separated without damaging components.
b. Air Line Piping Fabrication
1. Cut a section of new pipe (2) 1/16 in. (1.6 mm) smaller than damaged pipe section (6).
NOTE
Perform steps 2 and 3 before applying PVC adhesive.
2. Install two connectors (3) on new pipe section (2).
3. Install connectors (3) and new pipe section (2) on pipe ends (4) to ensure correct fit and then remove
connectors (3) and new pipe section (2).
NOTE
Clean ends of pipe with emery cloth before applying adhesive.
4. Apply PVC adhesive to one end of connectors (3) and both ends of new pipe section (2).
5. Install two connectors (3) with PVC adhesive coated ends inward, to new pipe section (2) and twist
components 70-90°. If an elbow (1) or tee (5) is being installed, twist components together 70-90°
and then turn components to their proper orientation. Allow PVC adhesive to dry.
6. Apply PVC adhesive to connectors (3) and pipe ends (4).
c. Installation
Install connectors (3) and new pipe section (2) on pipe ends (4) and twist 70-90°. Allow PVC adhesive
to dry.
11-244
TM 9-2320-280-20-3
I 11-166. NBC AIR LINE PIPING MAINTENANCE (Cont’d)
FOLLOW-ON TASK: Operate NBC system and check for leaks (TM 9-2320-280-10).
11-245
TM 9-2320-280-20-3
11-167. NBC GAS FILTER AND BRACKET REPLACEMENT

This task covers:
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools FM 3-4
General mechanic’s tool kit: FM 3-5
Equipment Condition
Materials/Parts NBC access door opened (TM 9-2320-280-10).
Four rivets (Appendix G, Item 185) General Safety Instructions
If filter has been used in a nuclear, biological, or
chemical (NBC) environment, special precautions
must be taken.
WARNING
NBC contaminated filters must be handled and disposed of only by
authorized and trained personnel. The unit commander or senior
officer in charge of maintenance personnel must ensure that
prescribed protective clothing (FM 3-4) is used, and prescribed
safety measures and decontamination procedures (FM 3-5) are
followed. The local unit SOP is responsible for final disposal of
contaminated air filters.
NOTE
● The procedures for replacing the NBC gas filter and bracket are
basically the same for M996, M996A1, M997, M997A1, and

M997A2 ambulances. This procedure covers NBC filter and
bracket in M997, M997A1, and M997A2 ambulances. The basic
differences in M996 and M996A1 ambulances are:
– PVC air line is replaced by flex tube.
— Bracket is installed on NBC door and secured with four
rivets and eight washers.
● Note direction of gas filter air flow arrow for installation.
1. Loosen two clamps (1) on ends of gas filter (9) and connectors (2).
2. Unhook two latches (8) from bracket (5) on gas filter (9).
3. Remove gas filter (9) from connectors (2) and bracket (5).
NOTE
Perform step 4 for M997, M997A1, and M997A2 vehicles only.
4. Remove four capscrews (7), lockwashers (6), bracket (5), and two spacers (4) from body (3). Disc
lockwashers (6).
11-246
TM 9-2320-280-20-3
11-167. NBC GAS FILTER AND BRACKET REPLACEMENT (Cont’d)
NOTE
Perform step 5 for M996 and M996A1 vehicles only.
5. Remove four rivets (10), eight washers (11), and bracket (5) from NBC door (12).
I b. Installation
NOTE
1. Install bracket (5) on NBC door (12) with eight washers (11) and four rivets (10).
NOTE
2. Intall two spacers (4) and bracket (5) on body (3) with four lockwashers (6) and capscrews (7).
3. Install gas filter (9) on connectors (2) and bracket (5) with latches (8).
4. Install ends of gas filter (9) on connectors (2) and tighten two clamps (1).
FOLLOW-ON TASK: Close NBC access door (TM 9-2320-280-10).
11-247
TM 9-2320-280-20-3
11-168. NBC PRECLEANED, PARTICULATE FILTER ASSEMBLY, AND BRACKET

REPLACEMENT
This task covers:
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools FM 3-4
General mechanic’s tool kit: FM 3-5

Equipment Condition
Materials/Parts NBC access door opened (TM 9-2320-280-10).
Four lockwashers (Appendix G, Item 130) General Safety Instructions
NBC contaminated filters must be handled and
disposed of only by trained personnel.
WARNING
NBC contaminated filters must be handled and disposed of only by auth-
orized and trained personnel. The unit commander or senior officer in
charge of maintenance personnel must ensure that prescribed protective
clothing (FM 3-4) is used, and prescribed safety measures and
decontamination procedures (FM 3-5) are followed. The local unit SOP is
responsible for final disposal of contaminated air filters.
NOTE
The procedures for replacing precleaned and particulate filter and filter
assembly and bracket are basically the same for M996, M996A1, M997,
M997A1, and M997A2 ambulances. This procedure covers precleaner
and particulate filter and bracket in M997, M997A1, and M997A2
ambulances. The basic differences in M996 and M996A1 ambulance are:
- The rigid PVC air line is replaced by flex tube and plastic clamps.
- Bracket is mounted on the floor of the NBC compartment and is
secured by four capscrews, washers, lockwashers, and nuts.
1. Disconnect lead and connector (para. 4-101).

2. Loosen two clamps (1) on precleaned and particulate filter assembly (7) and connectors (2).
3. Remove latch (9) and arms (10) on precleaned and particulate filter assembly (7) from
bracket (6).
4. Remove precleaner and particulate filter assembly (7) from connectors (2) and bracket (6).
NOTE
5. Remove four capscrews (5), lockwashers (4), and bracket (6) from body (3). Discard lockwashers (4).
NOTE
6. Remove four nuts (11), lockwashers (12), capscrews (14), washers (13), and bracket (6) from floor (15)
of NBC compartment. Discard lockwashers (12).
7. For shipping or decontamination purposes, slide clip (8) over intake holes in precleaned and
particuate filter assembly (7).
11-248
TM 9-2320-280-20-3
11-168. NBC PRECLEANED, PARTICULATE FILTER ASSEMBLY, AND BRACKET

REPLACEMENT (Cont’d)
8. Remove four screws (19), lockwashers (20), and manifold (16) from housing (18). Discard
lockwashers (20).
9. Remove filter (17) from filter housing (18).
NOTE
1. Install bracket (6) on body (3) with four lockwashers (4) and capscrews (5).
NOTE
2. Install bracket (6) on floor (15) of NBC compliment with four washers (13), capscrews (14),
3. Install filter (17) into filter housing (18).
4. Install manifold (16) on filter housing (18) with four lockwashers (20) and screws (19).
5. Slide clip (8) away from air intake holes in precleaned and particulate filter assembly (7).
6. Install precleaned and particulate filter assembly (7) on connectors (2) and bracket (6) with
arms (10) and latch (9).
7. Tighten two clamps (1) on precleaned and particulate assembly (7) and connectors (2).
8. Connect lead and connector (para. 4-101).
FOLLOW-ON TASK: Close NBC access door (TM 9-2320-280-10).
11-249
TM 9-2320-280-20-3
I 11-169. INTERCOM AND BRACKETS REPLACEMENT

This task covers:
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 TM 9-2320-280-24P
Tools
a. Removal
1. Disconnect intercom cable (11) from intercom control (10).
2. Remove two nuts (17), washers (16), capscrews (12), washers (13), and intercom control (10) from
intercom mounting bracket (6).
3. Disconnect cable (7) from audio amplifier (8).
4. Remove four nuts (3), washers (4), capscrews (9), washers (4), and audio amplifier (8) from intercom
mounting bracket (6).
5. Remove two nuts (14), washers (15), capscrews (20), and washers (21) from intercom mounting
bracket (6) and radio rack support (5).
6. Remove two nuts (18), washers (19), screws (2), and intercom mounting bracket (6) from radio rack (1).
NOTE
7. Disconnect intercom cable (11) from intercom control (22). Remove two capscrews (24), washers (25),
and intercom control (22) from wall (23).
NOTE
8. Disconnect intercom cable (11) from intercom control (26). Remove two nuts (29), washers (28),
reinforcement bracket (27), two capscrews (32), washers (31), and intercom control (26) from
body (30).
11-250
TM 9-2320-280-20-3
11-169. INTERCOM AND BRACKETS REPLACEMENT (Cont’d)
b. Installation
NOTE
1. Install intercom control (26) and reinforcement bracket (27) on body (30) with two washers (31),
capscrews (32), washers (28), and nuts (29). Connect intercom cable (11) t O intercom control (26).
NOTE
2. Install intercom control (22) on body (23) with two washers (25) and capscrews (24). Connect
intercom cable (11) to intercom control (22).
3. Install intercom mounting bracket (6) on radio rack support (5) with two washers (21),
4. Install intercom mounting bracket (6) on radio rack (1) with two screws (2), washers (19), and
nuts (18).
5. Install audio amplifier (8) on intercom mounting bracket (6) with four washers (4), capscrews (9),
washers (4), and nuts (3). Connect cable (7) to audio amplifier (8).
6. Install intercom control (10) on intercom mounting bracket (6) with two washers (13),
capscrews (12), washers (16), and nuts (17). Connect intercom cable (11) to intercom control (10).
11-251
TM 9-2320-280-20-3
11-170. REAR DRIP RAIL REPLACEMENT

This task covers:
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 Sealant (Appendix C, Item 38)
Nine rivets (Appendix G, Item 177)
Tools
NOTE
Remove nine rivets (2) and drip rail (3) from body (1).
Apply sealant to drip rail (3) and install drip rail (3) on body (1) with nine rivets (2).
11-252
TM 9-2320-280-20-3
11-171. RADIO ANTENNA MOUNT REPLACEMENT (M996, M996A1)

This task covers:
INITIAL SETUP:
M996, M996A1 TM 9-2320-280-24P
General mechanic’s tool kit: Antenna removed (para. 12-137).
Materials/Parts
Six lockwashers (Appendix G, Item 109)
Remove six capscrews (2), lockwashers (1), antenna mount (3), and seal (4) from roof (5). Discard
lockwashers (1).
b. Installation
Install seal (4) and antenna mount (3) on roof (5) with six lockwashers (1) and capscrews (2)
FOLLOW-ON TASK: Install antenna (para. 12-137).
11-253
TM 9-2320-280-20-3
11-172. RADIO ANTENNA MOUNT REPLACEMENT (M997, M997A1 , M997A2)

This task covers:
INITIAL SETUP:
M997, M997A1, M997A2 TM 9-2320-280-24P
General mechanic’s tool kit: Antenna removed (para. 12-137).
Materials/Parts
Three lockwashers (Appendix G, Item 108)
a. Removal
1. Remove capscrew (7), lockwasher (8), seal (2), cable clip (9), and ground strap (6) from antenna
mount (1) and roof (10). Discard lockwasher (8).
2. Remove two capscrews (5), lockwashers (4), washers (3), antenna mount (1), and seal (2) from roof
(10). Discard lockwashers (4).
NOTE
Clean ground strap at point of interior body contact to bare metal
to ensure good antenna ground.
1. Install seal (2) and antenna mount (1) on roof (10) with two washers (3), lockwashers (4), and
capscrews (5).
2. Install cable clip (9), ground strap (6), seal (2), and antenna mount (1) on roof (10) with lockwasher (8)
and capscrew (7).
FOLLOW-ON TASK: Install antenna (para. 12-137).
11-254
TM 9-2320-280-20-3
11-173. STOWAGE NET ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
M997, M997A1, M997A2 TM 9-2320-280-24P
Tools
1. Slide two spring-loaded caps (4) on front support bar (7) inward, away from wall mounts (5), and
slide flange (8) up and out of wall mounts (5).
2. Remove five stowage strap hooks (1) from footman loops (6) and remove stowage net (2) and front
support bar (7).
3. Unfasten two straps (3) and remove stowage net (2) from front support bar (7).
I b. Installation
1. Install stowage net (2) on front support bar (7) with two straps (3).
2. Install five stowage strap hooks (1) on footman loops (6).
3. Slide two spring-loaded caps (4) inward, along front support bar (7), and install flange (8) on wall
mounts (5).
11-255
TM 9-2320-280-20-3
11-174. RED CROSS PLACARD RETAINING CLIP REPLACEMENT

This task covers:
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 TM 9-2320-280-24P
Tools
Remove two capscrews (1) and retaining clip (2) from body (3).
Install retaining clip (2) on body (3) with two capscrews (1).
11-256
TM 9-2320-280-20-3
11-175. RED CROSS PLACARD REPLACEMENT

This task covers:
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 Seven rivets (Appendix G, Item 188)
Tools
NOTE
● Rear door, body side, body top, and front red cross placards are
removed and installed basically the same. This procedure covers
an M997, M997A1, and M997A2 rear door red cross placard.
a. Removal
Remove twelve rivets (1) and red cross placard (2) from rear door (3).
b. Installation
Install red cross placard (2) to rear door (3) with twelve rivets (1).
11-257
TM 9-2320-280-20-3
11-176. EXTERIOR STOWAGE DOOR REPLACEMENT

This task covers:
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 Adhesive (Appendix C, Item 3)
Fourteen rivets (Appendix G, Item 188)
Tools Twelve rivets (Appendix G, Item 189)
TM 9-2320-280-24P
NOTE
● Replacement procedures for left and right exterior stowage doors are
basically the same. This procedure covers the left stowage door.
1. Remove seven rivets (2), hinge (6), and door (8) from body (5).
2. Remove seven rivets (1) and hinge (6) from door (8).
3. Remove four rivets (11) and two rubber latches (10) from door (8).
4. Remove four rivets (9) and two brushguards (12) from door (8).
5. Remove four rivets (3) and two catches (4) from body (5).
6. Remove seal (7) from door (8). Discard seal (7) if damaged.
1. Apply adhesive to seal (7) and install seal (7) on door (8).
2. Install two catches (4) on body (5) with four rivets (3).
3. Install two brushguards (12) on door (8) with four rivets (9).
4. Install two rubber latches (10) on door (8) with four rivets (11).
5. Install hinge (6) on door (8) with seven rivets (1).
6. Install hinge (6) and door (8) on body (5) with seven rivets (2).
11-258
TM 9-2320-280-20-3
11-177. ATTENDANT SEAT STOWAGE BRACKETS REPLACEMENT I

This task Covers:
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) Attendant seat removed from stowed position
(TM 9-2320-280-10).
Materials/Parts
NOTE
● Replacement procedures for attendant seat stowage brackets are
basically the same for M996, M996A1, M997, M997A1, and M997A2
ambulances, with the exception of the strap assembly. The strap
assembly is mounted in a vertical position on the body of the M996
and M996A1 ambulance. This procedure covers the attendant seat
stowage brackets in the M997, M997A1, and M997A2 ambulances.
a. Removal
1. Remove four screws (3) and two footman loops (5) from body (1), and remove strap assembly (2)
from footman loops (5).
2. Remove eight rivets (6) and two brackets (7) from body (1).
3. Inspect blind rivet (4) for damage. Replace if damaged.
I b. Intallation
1. Install two brackets (7) on body (1) with eight rivets (6).
2. Install strap assembly (2) on two footman loops (5) and install footman loops (5) on body(1)with
four screws (3).
FOLLOW-ON TASK: Stow attendant seat (TM 9-2320-280-10).
11-259
TM 9-2320-280-20-3
I 11-178. REAR DOOR VENT ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
M996, M996A1 Sixteen rivets (Appendix G, Item 188)
NOTE
1. Remove two rivets (1) and retaining clip (2) from door (3).
2. Remove fourteen rivets (5) and vent assembly (4) from door (3).
b. Installation
1. Install vent assembly (4) on door (3) with fourteen rivets (5).
2. Install retaining clip (2) on door (3) with two rivets (1).
11-260
TM 9-2320-280-20-3
11-179. MEDICAL STOWAGE COVER AND LATCH REPLACEMENT

This task covers:
lNITIAL SETUP:
M996, M996A1 Nine rivets (Appendix G, Item 188)
Tools
NOTE
1. Remove nine rivets (7) and cover and hinge assembly (1) from body (6).
2. Remove two rivets (3) and catch (2) from body (6).
3. Remove two rivets (5) and latch (4) from cover and hinge assembly (1).
1. Install latch (4) on cover and hinge assembly (1) with two rivets (5).
2. Install catch (2) on body (6) with two rivets (3).
3. Install cover and hinge assembly (1) on body (6) with nine rivets (7).
11-261
TM 9-2320-280-20-3
11-180. EDGE PROTECTOR REPLACEMENT

This task covers:
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 TM 9-2320-280-24P
Tools
Pry edge protector (2) from bulkhead (1) and remove edge protector (2).
b. Installation
Install edge protector (2) by pressing edge protector (2) onto bulkhead (1).
11-262
TM 9-2320-280-20-3
1 1 - 1 8 0 . 1 . SPREADER BAR TIEDOWN REPLACEMENT

This task covers:
INITIAL SETUP:
Applicable Models
_______________ Materials/Parts
M996, M996A1, M997, M997A1, Lockwasher (Appendix G, Item 114.1)
M997A2 Adhesive sealant (Appendix C, Item 38)
Tools
a. Removal
Remove capscrew (4), lockwasher (3), and spreader bar tiedown (2) from body (1). Discard lockwasher (3).
b. Installation
Apply adhesive sealant to capscrew (4) and install spreader bar tiedown (2) on body (1) with lock-
washer (3) and capscrew (4). Tighten capscrew (4) to 45-55 lb-ft (61-75 N•m).
Change 1 11-262.1/(11-262.2 blank)

TM 9-2320-280-20-3
11-181. AMBULATORY PATlENT SEAT REPLACEMENT

This task covers:
INITIAL SETUP:
M996, M996A1 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) Ambulatory patient seat opened (TM 9-2320-280-10).
Materials/Parts
Two rivets (appendix G, Item 187)
NOTE
a. Removal
1. Remove two screws (5) from seat brace (2) and seat frame (1).
2. Remove two rivets (4) and seat brace (2) from seatback (3).
3. Inspect blind rivet (6) for damage. Replace if damaged.
4. Remove four rivets (11) and seat support (7) from seatback (3).
5. Remove two rivets (10), latch (8), and shim (9) from seat support (7).
11-263
TM 9-2320-280-20-3
11-181. AMBULATORY PATIENT SEAT REPLACEMENT (Cont’d)
6. Remove four screws (8) and large cushion (2) from seatback (1).
7. Remove two screws (8) and small cushion (3) from seatback (1).
8. Remove twelve nuts (5), washers (6), and seat cushion (4) from seat base (7).
b. Installation
1. Install seat cushion (4) on seat base (7) with twelve washers (6) and nuts (5).
2. Install small cushion (3) on seatback (1) with two screws (8).
3. Install large cushion (2) on seatback (1) with four screws (8).
4. Install latch (14) and shim (15) on seat support (13) with two rivets (16).
5. Install seat support (13) on seatback (1) with four rivets (17).
6. Install seat brace (10) on seatback (1) with two rivets (11).
7. Install seat brace (10) on seat frame (9) with two screws (12).
FOLLOW-ON TASK: Close ambulatory patient seat (TM 9-2320-280-10).
11-264
TM 9-2320-280-20-3
11-182. AMBULATORY PATlENT SEAT REAR CLOSEOUT PANEL REPLACEMENT

This task covers:
INITIAL SETUP:
M996, M996A1 TM 9-2320-280-24P
Tools
1. Remove two screws (9) from seat brace assembly (1) and closeout panel (4). Push seat brace
assembly (1) up and out of way.
2. Remove two screws (7), washers (6), and seat stop (5) from closeout panel (4) and litter rack (2).
3. Remove three screws (8) and (3) and closeout panel (4) from litter rack (2).
b. Installation
1. Install closeout panel (4) on litter rack (2) with three screws (8) and (3).
2. Install seat stop (5) on closeout panel (4) with two washers (6) and screws (7).
3. Install seat brace (1) on closeout panel (4) with two screws (9).
11-265
TM 9-2320-280-20-3
I 11-183. NBC DOOR REPLACEMENT (M996, M996A1) I

This task covers:
lNITIAL SETUP:
Applicable Modes Manual References
M996, M996A1 TM 9-2320-280-24P
General mechanic’s tool kit: NBC gas filters and brackets removed
Materials/Parts
Ten rivets (Appendix G, Item 188)
NOTE
1. Remove five rivets (13), door (10), and hinge (12) from body (1).
2. Remove five rivets (11) and hinge (12) from door (10).
3. Remove two screws (7), nut and lockwasher assemblies (3), footman loop (9), and strap (8) from
door (10). Discard nut and lockwasher assemblies (3).
4. Remove two wing head screws (6) and retainers (4) from door (10). Inspect retainers (4) for damage,
replace if damaged.
5. Remove seals (2) and (5) from door (10).
b. Installation
1. Install seals (2) and (5) on door (10).
2. Install two wing head screws (6) on door (10) with retainers (4).
3. Install strap (8) and footman loop (9) on door (10) with two screws (7) and nut and lockwasher
assemblies (3).
4. Install hinge (12) on door (10) with five rivets (11).
5. Install door (10) and hinge (12) on body (1) with five rivets (13).
11-266
TM 9-2320-280-20-3
I 11-183. NBC DOOR REPLACEMENT (M996, M996A1) (Cont’d)
FOLLOW-ON TASK: Install NBC gas filters and brackets (para. 11-167).
11-267
TM 9-2320-280-20-3
11-184. AIR INTAKE COMPARTMENT PANELS REPLACEMENT

This task covers:
INITIAL SETUP:
M997, M997A1, M997A2 TM 9-2320-280-24P
Took Equipment Condition
General mechanic’s tool kit: ● Blower housing opened (para. 11-198).
automotive (Appendix B, Item 1) . Front cover panel removed (para. 11-187).
Materials/Parts
Seven lockwashers (Appendix G, Item 109)
a. Removal
1. Remove six screws (2) from panel (3) and condenser fan housing (4).
2. Remove three screws (5), lockwashers (6), and panel (3) from panel (7). Discard lockwashers (6).
3. Remove two screws (1) and lockwashers (15) from panel (7) and air intake assembly (14). Discard
lockwashers (15).
4. Remove two nuts (13), washers (12), screws (8), washers (10), lockwashers (9), and panel (7) from
body (11). Discard lockwashers (9).
1. Install panel (7) on body (11) and air intake assembly (14) with two washers (10), lockwashers (9),
screws (8), washers (12), and nuts (13).
2. Install panel (7) on air intake assembly (14) with two lockwashers (15) and screws (1).
3. Install panel (3) on panel (7) and fan housing (4) with three lockwashers (6) and screws (5).
4. Secure panel (3) to fan housing (4) with six screws (2).
FOLLOW-ON TASKS: ● Close blower housing (para. 11-198).

c Install front cover panel (para. 11-187).
11-268
TM 9-2320-280-20-3
11-185. AIR INTAKE DUCT DOOR REPLACEMENT 1

This task covers:
a. Removal b. Installtion
INITIAL SETUP:
M997, M997A1, M997A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) . Air intake filter removed (TM 9-2320-280-10).
● Blower housing opened (para. 11-198).
Materials/Parts
NOTE
Evaporator intake duct door and heater intake duct door are
replaced basically the same. This procedure covers the evaporator
duct door.
1. Remove pushnut (6) and slide control cable (5) off arm (7). Discard pushnut (6).
2. Remove two capscrews (4) and lockwashers (3) from duct door (2) and intake duct (8). Discard
lockwashers (3).
3. Slide duct door (2) right, and remove duct door (2) and bushing (1) from intake duct (8) and
bracket (9).
1. Install bushing (1) on bracket (9).

2. Install arm (7) through intake duct (8) and slide duct door (2) left into bushing (1).
3. Install duct door (2) on intake duct (8) with two lockwashers (3) and capscrews (4).
4. Slide control cable (5) onto arm (7) with pushnut (6).
FOLLOW-ON TASKS: . Install air intake filter (TM 9-2320-280-10).

● Adjust duct door control cable (para. 11-199).
11-269
TM 9-2320-280-20-3
I 11-186. AIR lNLET/OUTLET GRILLE REPLACEMENT

This task covers:
INITIAL SETUP:
M997, M997A1, M997A2 Adhesive (Appendix C, Item 3)
Tools Ten lockwashers (Appendix G, Item 119)
TM 9-2320-280-24P
NOTE
Procedures for replacing inlet and outlet grilles are basically the
same. This procedure covers the outlet grille.
Remove ten screws (3), lockwashers (4), washers (5), grille (6), and gasket (1) from body (2). Discard
gasket (1) and lockwashers (4). Clean grille (6) to remove remaining adhesive.
NOTE
Ensure outer louvers on grille are angled downward for installation.

Apply adhesive to grille (6) at gasket (1) mating surface. Install gasket (1) and grille (6) on body (2) with
ten washers (5), lockwashers (4), and screws (3).
11-270
TM 9-2320-280-20-3
11-187. FRONT COVER PANEL REPLACEMENT

This task covers
a. Removal b. Instllation
INITIAL SETUP:
M997, M997A1, M997A2 Six lockwashers (Appendix G, Item 119)
a. Removal
1. Remove two capscrews (1), lockwashers (2), and washers (3) from panel (9) and panel (4). Discard
lockwashers (2).
2. Remove four screws (8), lockwashers (7), washers (6), and panel (9) from body (5). Discard
lockwashers (7).
1. Install panel (9) on body (5) with four washers (6), lockwashers (7), and screws (8).
2. Install panel (9) on panel (4) with two washers (3), lockwashers (2), and capscrews (1).
11-271
TM 9-2320-280-20-3
11-188. REAR COVER PANEL REPLACEMENT

I
This task covers:
INITIAL SETUP:
M997, M997A1, M997A2 Nine lockwashers (Appendix G, Item 119)
1. Remove four capscrews (7) and washers (8) from panel (1) and blower housing (6).
2. Remove nine screws (5), lockwashers (4), washers (3), and panel (1) from body (2). Discard
lockwashers (4).
1. Install panel (1) on body (2) with nine washers (3), lockwashers (4), and screws (5).
2. Install panel (1) on blower housing (6) with four washers (8) and capscrews (7).
11-272
TM 9-2320-280-20-3
I 11-189. HEATER EXHAUST PIPE REPLACEMENT (M997, M997A1, M997A2)

This task covers:
INITIAL SETUP
M997, M997A1, M997A2 TM 9-2320-280-24P
.
Tools General Safety Instructions
General mechanic’s tool kit: Do not touch hot exhaust system with bare hands.
Materials/Parts
WARNING
Do not touch hot exhaust system components with bare hands.
Severe injury will result.
NOTE
1. Remove two rivets (5) from exhaust pipe (1) and body (2).
2. Remove exhaust pipe (1) from opening (3) in body (2)
1. Install exhaust pipe (1) on opening (3) in body (2) and onto heater exhaust outlet (4).
2. Install exhaust pipe (1) on body (2) with two rivets (5).
11-273
TM 9-2320-280-20-3
11-190. HEATER REPLACEMENT (M997, M997A1, M997A2)

This task covers:
INITIAL SETUP:
M997, M997A1, M997A2 TM 9-2320-280-24P
General mechanic’s tool kit: ● Blower housing open (para. 11-198).
automotive (Appendix B, Item 1) ● Battery ground cable disconnected (para. 4-73).

One mechanic Diesel fuel is highly flammable. Do not perform
One assistant this procedure near fire, flames, or sparks.
WARNING
Diesel fuel is highly flammable. Do not perform this procedure
near fire, flames, or sparks. Severe injury or death may result.
NOTE
● Have drainage container ready to catch fuel.
● Cover or plug all open connections immediately after
disconnection to prevent contamination. Remove all covers or
plugs prior to connection.
1. Disconnect plug (11) from heater receptacle (12).

2. Loosen clamp (8) and disconnect hose (9) from heater outlet (7).
3. Disconnect fuel line (13) from heater (14) and allow fuel to drain into container.
4. Remove two clamps (2) from heater (14) and mounting brackets (4).
5. Turn two dzus fasteners (16) and remove cover (15) from heater (14).
6. Remove heater (14) by lifting rear of heater (14) up and pulling heater (14) out from exhaust pipe (6)
and sliding heater (14) to the right and out of intake assembly (1).
7. Inspect seal (5) for presence and damage. Replace if missing or damaged.
8. Remove four screws (10) and outlet (7) from heater (14).
I b. Installation
1. Install outlet (7) on heater (14) with four screws (10).
2. Install two clamps (2) on mounting brackets (4).
3. Install heater (14) on mounting brackets (4), ensuring heater exhaust outlet (3) is installed into
exhaust pipe (6), and clamps (2) are wrapped around heater (14).
4. Slide heater (14) into intake assembly (1) opening and on mounting brackets (4) with two clamps (2).
5. Connect fuel line (13) to heater (14).
6. Connect hose (9) to heater outlet (7) and tighten clamp (8).
7. Connect plug (11) to heater receptacle (12).
8. Install cover (15) on heater (14) with two dzus fasteners (16).
11-274
TM 9-2320-280-20-3
I 11-190. HEATER REPLACEMENT (M997, M997A1, M997A2) (Cont’d)
FOLLOW-ON TASKS: “ Close blower housing (para 11-198).

. Connect battery ground cable (para. 4-73).
11-275
TM 9-2320-280-20-3
11-191. HEATER OUTLET HOSE REPLACEMENT (M997, M997A1, M997A2)

I
This task covers:
lNITIAL SETUP:
M997, M997A1, M997A2 TM 9-2320-280-24P
General mechanic’s tool kit: Blower housing open (para. 11-198).
1. Loosen clamp (5) and disconnect hose (4) from heater outlet (1).
2. Loosen clamp (2) and disconnect hose (4) from heat duct (3).
3. Remove hose (4) by pulling out from behind and over top of heater (6).
4. Remove clamps (2) and (5) from hose (4).
1. Install clamps (2) and (5) on hose (4).

2. Route hose (4) over top of and behind heater (6) in mounting position.
3. Connect hose (4) to heat duct (3) and tighten clamp (2).
4. Connect hose (4) to heater outlet (1) and tighten clamp (5).
11-276
TM 9-2320-280-20-3
I 11-191. HEATER OUTLET HOSE REPLACEMENT (M997, M997A1, M997A2) (Cont’d) I
FOLLOW-ON TASK: Close blower housing (para. 11-198).
11-277
TM 9-2320-280-20-3
11-192. HEATER FUEL FILTER REPLACEMENT I

This task covers:
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 ● Stowage compartment door open
(TM 9-2320-280-10).
Tools ● Close fuel shut-off valve
Materials/Parts Diesel fuel is highly flammable. Do not perform
Sealing compound (Appendix C, Item 44) this procedure near fire, flames, or sparks.
TM 9-2320-280-10
TM 9-2320-280-24P
WARNING
near fire, flames, or sparks. Severe injury or death will result.
NOTE
● Have drainage container ready to catch fuel.

● Cover or plug all open connections immediately after disconnection
to prevent contamination. Remove all covers or plugs prior to
connection.
a. Removal
1. Disconnect two fuel lines (5) from filter (7) and allow fuel to drain.
2. Remove two nuts (4), lockwashers (3), washers (2), screws (8), filter (7), and spacers (1) from
panel (6). Discard lockwashers (3).
NOTE
Apply sealing compound to threads of all fuel line joints before
installation.
1. Install two spacers (1) and filter (7) on panel (6) with two screws (8), washers (2), lockwashers (3),
and nuts (4).
2. Connect two fuel lines (5) to filter (7).
11-278
TM 9-2320-280-20-3
11-192. HEATER FUEL FILTER REPLACEMENT (Cont’d)
FOLLOW-ON TASKS: ● Open fuel shut-off valve (TM 9-2320-280-10).

. Bleed heater fuel system (para. 11-195).
c Close stowage compartment door (TM 9-2320-280-10).
11-279
TM 9-2320-280-20-3
11-193. HEATER FUEL LINES REPLACEMENT

This task covers:
a. Heater Fuel Line Replacement f. Bulkhead Coupling Replacement
b. Cab Fuel Line Replacement Bulkhead Fuel Line Replacement
c. Shutoff Valve Replacement h. Pump Fuel Line Replacement
d. “B” Beam Fuel Line Replacement i. Tank Fuel Line and Supply Tube Replacement
e. Filter Fuel Line Replacement
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 TM 9-2320-280-24P
General mechanic’s tool kit Do not perform this procedure near fire, flames, or
automotive (Appendix B, Item 1) sparks.
Materials/Parts
Tiedown strap (Appendix G, Item 241)
WARNING
Diesel fuel is highly flammable. Do not perform this procedure near fire,
flames, or sparks. Severe injury or death will result.
NOTE
c Fuel line replacement is basically the same on M996, M996A1, M997,
M997A1, and M997A2 vehicles. This procedure covers M997, M997A1,
and M997A2 vehicles.
l Have drainage container ready to catch fuel.
c Apply sealing compound in threads of all fuel line joints before installation.
l Cover or plug all open connections immediately after removal to prevent
contamination. Remove all covers or plugs prior to connection

a. Heater Fuel Line Replacement
1. Open blower housing (para. 11-198).
2. Disconnect fuel line (1) from heater (2) and allow fuel to drain. Remove tiedown strap (3) from fuel
line (1) and control cables (4). Discard tiedown strap (3).
3. Disconnect fuel line (1) from cab fuel line (8), allow fuel to drain, and remove fuel line (1).
4. Install fuel line (1) through grommet (14) and connect to cab fuel line (8).
6. Install fuel line (1) on control cables (4) with tiedown strap (3).
7. Close blower housing (para. 11-198).
b. Cab Fuel Line Replacement
1. Remove capscrew (11), lockwasher (10), washer (9), harness clamp (12), and clamp (6) from
A/C lines (5), body (13), and fuel line (8). Discard lockwasher (10).
2. Disconnect fuel line (8) from shutoff valve (7) and allow fuel to drain.
3. Disconnect fuel line (8) from heater fuel line (1) and remove fuel line (8) from vehicle.
4. Install fuel line (8) in vehicle and connect to heater fuel line (1).
11-280
TM 9-2320-280-20-3
11-193. HEATER FUEL LINES REPLACEMENT (Cont’d) I

5. Connect fuel line (8) to shutoff valve (7).
6. Install clamp (6) on A/C lines (5), fuel line (8), and body (13) with harness clamp (12), washer (9),
lockwasher (10), and screw (11).
11-281
TM 9-2320-280-20-3
11-193. HEATER FUEL LINES REPLACEMENT (Cont’d) I

c. Shutoff Valve Replacement
1. Disconnect cab fuel line (1) from shutoff valve (2) and allow fuel to drain.
2. Close shutoff valve (2), disconnect “B” beam fuel line (3) from shutoff valve (2), and remove shutoff
valve (2).
3. Connect “B” beam fuel line (3) to shutoff valve (2).
4. Connect cab fuel line (1) to shutoff valve (2) and open valve (2).
d. “B” Beam Fuel Line Replacement

L Close shutoff valve (2) and disconnect fuel line (3) from shutoff valve (2).
2. Disconnect fuel line (3) from filter (6), allow fuel to drain, and remove fuel line (3).
3. Connect fuel line (3) between “B” beam (5) and seal (4) and connect to filter (6).
4. Connect fuel line (3) to shutoff valve (2) and open valve (2).
e. Filter Fuel Line Replacement

1. Disconnect fuel line (7) from filter (6) and allow fuel to drain.
2. Disconnect fuel line (7) from bulkhead connector (13).
3. Connect fuel line (7) to bulkhead connector (13).
4. Connect fuel line (7) to filter (6).
f. Bulkhead Coupling Replacement

1. Remove fuel tank (para. 3-24).
2. Disconnect filter fuel line (7) from bulkhead connector (13) and allow fuel to drain.
3. Disconnect bulkhead fuel line (8) from elbow (9).
4. Remove elbow (9) from coupling half (12).
5. Remove coupling nut (10), washer (11), and coupling half (12) from tunnel (14).
6. Remove bulkhead connector (13) from coupling half (12).
7. Install bulkhead connector (13) on coupling half (12).
8. Install coupling half (12) to tunnel (14) with washer (11) and coupling nut (10).
9. Install elbow (9) on coupling half (12).
10. Connect bulkhead fuel line (8) to elbow (9).
11. Connect filter fuel line (7) to bulkhead connector (13).
12. Install fuel tank (para. 3-24).
11-282
TM 9-2320-280-20-3
11-193. HEATER FUEL LINES REPLACEMENT (Cont’d)
11-283
TM 9-2320-280-20-3
I 11-193. HEATER FUEL LINES REPLACEMENT (Cont’d) 1

g. Bulkhead Fuel Line Replacement

2. Disconnect fuel line (2) from elbow (6) and allow fuel to drain.
3. Disconnect fuel line (2) from pump (1) and remove fuel line (2).
4. Connect fuel line (2) to pump (1).
5. Connect fuel line (2) to elbow (6).
h. Pump Fuel Line Replacement
1. Loosen clamp (4) and disconnect hose (5) from fuel line (3). Allow fuel to drain.
2. Disconnect fuel line (3) from pump (1).
3. Connect fuel line (3) to pump (1).
4. Connect hose (5) to fuel line (3) and tighten clamp (4).
i. Tank Fuel Line and Supply Tube Replacement

2. Remove capscrew (10) clamp (11) and fuel line (9) from tank (8).
3. Remove fuel line (9) from supply tube (7).
4. Remove supply tube (7) from tank (8).
5. Install supply tube (7) on tank (8).
6. Connect fuel line (9) to supply tube (7).
7. Install clamp (11) on fuel line (9) and tank (8) with capscrew (10).
11-284
TM 9-2320-280-20-3
11-193. HEATER FUEL LINES REPLACEMENT (Cont’d)
FOLLOW-ON TASK: Bleed heater fuel system (para. 11-195).
11-285
TM 9-2320-280-20-3
11-194. HEATER FUEL PUMP REPLACEMENT

This task covers:
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 TM 9-2320-280-24P
General mechanic’s tool kit: Battery ground cable disconnected (para. 4-73).
Materials/Parts Do not perform this procedure near fire, flames, or
Sealing compound (Appendix C, Item 44) Sparks.
TWo locknuts (Appendix G, Item 58)
WARNING
NOTE
. Have drainage container ready to catch fuel.
l Cover or plug all open connections immediately after
disconnection to prevent contamination. Remove covers or plugs

prior to connection.
l Apply sealing compound to threads of all fuel line joints before
installation.
1. Disconnect two fuel lines (8) from elbow (7) and fitting (9) and allow fuel to drain.
2. Remove tiedown strap (1) from fuel pump lead (13) and dipstick tube (2). Discard tiedown
strap (1).
3. Disconnect fuel pump lead (13) from control box lead (12).
4. Remove two locknuts (11), washers (3), capscrews (4), washers (3), fuel pump (6), and ground
terminal (5) from capacitor clamp (14) and bracket (10). Discard locknuts (11).
5. Remove elbow (7) and fitting (9) from fuel pump (6).
b. Installation
1. Install elbow (7) and fitting (9) on fuel pump (6).
2. Install fuel pump (6) on bracket (10) and capacitor clamp (14) with ground terminal (5), two
washers (3), capscrews (4), washers (3), and locknuts (11).
3. Connect two fuel lines (8) to elbow (7) and fitting (9).
4. Connect fuel pump lead (13) to control box lead (12) and install fuel pump lead (13) on dipstick
tube (2) with tiedown strap (1).
11-286
TM 9-2320-280-20-3
11-194. HEATER FUEL PUMP REPLACEMENT (Cont’d)

. Bleed heater fuel system (para. 11-195).
11-287
TM 9-2320-280-20-3
11-195. HEATER FUEL SYSTEM BLEEDING

This task covers:
Bleeding
INITIAL SETUP:
M997, M997A1, M997A2 TM 9-2320-280-24P
General mechanic’s tool kit: Blower housing open (para. 11-198).
Materials/Parts Do not perform this procedure near fire, flames, or
Sealing compound (Appendix C, Item 45) sparks.
Personnel Required
One mechanic
One assistant
WARNING
NOTE
Q Have drainage container ready to catch fuel.
Q Apply compound to threads of all fuel line joints before
1. Disconnect heater fuel line (4) from heater (3).

2. Place end of fuel line (4) in drainage container.
3. Place heater rotary switch (1) on control box (2) to “RUN” position. Hold switch (1) in ‘RUN” position
until fuel flows free of air bubbles.
4. Place switch (1) to “OFF” position.
11-288
TM 9-2320-280-20-3
11-195. HEATER FUEL SYSTEM BLEEDING (Cont’d)
11-289
TM 9-2320-280-20-3
11-196. FLOOR HEAT DUCT LOUVER REPLACEMENT
This task covers:

a. Removal
b. Installation
INITIAL SETUP:
Applicable Models
Manual Reference
M997, M997A1, M997A2
TM 9-2320-280-24P
Tools
Remove four screws (3) and louver (2) from floor heat duct (1).
Install louver (2) on floor heat duct (1) with four screws (3).
11-290
TM 9-2320-280-20-3
11-197. BLOWER MOTOR RESISTOR REPLACEMENT

This task covers:
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 l Battery ground cable disconnected (para. 4-73).
l Blower housing open (para. 11-198).

Tools . Heater compartment panel removed
General mechanic’s tool kit: (M996 and M996A1 vehicles only) (para. 11-204).
Manual References
TM 9-2320-280-24P
NOTE
M996, M996A1, M997, M997A1, and M997A2 blower motor
resistors are replaced basically the same. This procedure covers
M997, M997A1, and M997A2 vehicles only.
1. Disconnect plug (1) from resistor (3).

2. Remove two screws (4) and resistor (3) from blower housing (2).
1. Install resistor (3) on blower housing (2) with two screws (4).
2. Connect plug (1) to resistor (3).
w
FOLLOW-ON TASKS: l Close blower housing (para. 11-198).
l Connect battery ground cable (para. 4-73).
l Heater compartment panel installed (M996 and M996A1 vehicles only)
(para. 11-204).
11-291
TM 9-2320-280-20-3
11-198. BLOWER MOTOR AND HOUSING MAINTENANCE

This task covers:
a. Opening Blower Housing d. Blower Housing Installation
b. Closing Blower Housing e. Blower Motor Removal
c. Blower Housing Removal f. Blower Motor Installation
INITIAL SETUP:
M997, M997A1, M997A2 TM 9-2320-280-24P
General mechanic’s tool kit: l Rear cover panel removed (para. 11-188).
automotive (Appendix B, Item 1) l Battery ground cable disconnected (para. 4-73).
Materials/Parts
Eleven lockwashers (Appendix G, Item 109)
a Opening Blower Housing

1. Remove nut and lockwasher assembly (3), washer (4), and capscrew (11) from blower housing (2) and
body (13). Discard nut and lockwasher assembly (3).
2. Release two latches (14) from blower housing (2) and evaporator duct (1) and swing blower
housing (2) open.
b. Closing Blower Housing
1. Swing blower housing (2) closed and secure to evaporator duct (1) with two latches (14).
2. Install blower housing (2) on body (13) with capscrew (11), washer(4), and nut and lockwasher assembly (3).
c. Blower Housing Removal
1. Perform step a.
NOTE
2. Disconnect four control box leads (6) from blower motor leads (5).
3. Remove capscrew (10), lockwasher (9), washer (8), and clamp (7) from blower housing (2). Discard
lockwasher (9).
4. Remove two capscrews (19) and lockwashers (18) from plate (20) and evaporator duct (1). Discard
lockwashers (18).
5. Remove two screws (21), lockwashers (15), and plate (20) from blower housing (2) and evaporator
duct (1). Discard lockwashers (15).
6. Remove four capscrews (16), lockwashers (17), and blower housing (2) from evaporator duct (1).
d. Blower Housing Installation
1. Install blower housing (2) on evaporator duct (1) with four lockwashers (17) and capscrews (16).
2. Install plate (20) on blower housing (2) and evaporator duct (1) with two lockwashers (15) and
screws (21).
3. Install plate (20) on evaporator duct (1) with two lockwashers (18) and capscrews (19).
4. Install clamp (7) and control box harness (12) on blower housing (2) with washer (8), lockwasher (9),
and capscrew (10).
11-292
TM 9-2320-280-20-3
11-198. BLOWER MOTOR AND HOUSING MAINTENANCE (Cont’d)
5. Connect four control box leads (6) to blower motor leads (5).
6. Perform step b.
11-293
TM 9-2320-280-20-3
a Blower Motor Removal
1. Perform step a.
NOTE
2. Disconnect two blower motor leads (10) from leads (1).

3. Remove five screws (8), blower motor (9), and bracket (7) from housing (2).
4. Remove setscrew (4) and fan (3) from motor (9).
5. Remove two nuts (5), lockwashers (6), and motor (9) from motor bracket (7). Discard lockwashers (6).
f. Blower Motor Installation

1. Install motor (9) on motor bracket (7) with two lockwashers (6) and nuts (5).
2. Install fan (3) on motor (9) with setscrew (4).
NOTE
Ensure fan rotates freely before securing.
3. Install blower motor (9) on housing (2) with five screws (8).
4. Connect two blower motor leads (10) to leads (1).
5. Perform step b.
11-294
TM 9-2320-280-20-3
FOLLOW-ON TASKS: s Install rear cover panel (para. 11-188).

11-295
TM 9-2320-280-20-3
11-199. DUCT DOOR CONTROL CABLES MAINTENANCE

This task covers:
a. Evaporator Intake Cable Removal e. Heater Intake Cable Removal
b. Evaporator Intake Cable Installation f. Heater Intake Cable Installation
c. Heater/Air-Conditioning Outlet Cable Removal g. Cable Adjustment
d. Heater/Air-Conditioning Outlet Cable Installation
INITIAL SETUP:
M997, M997A1, M997A2 TM 9-2320-280-10
TM 9-2320-280-24P
Took
automotive (Appendix B, Item 1) l Blower housing open (para. 11-198).
c Battery ground cable disconnected (para. 4-73).

Materials/Parts l Control box levers positioned to UNIT OFF and
Ten lockwashers (Appendix G, Item 118) A/C-VENT (TM 9-2320-280-10).
Six pushnuts (Appendix G, Item 170)
a Evaporator Intake Cable Removal

1. Remove pushnut (3) and disconnect cable loop (5) from duct door arm (6). Discard pushnut (3).
2. Remove screw (1), lockwasher (2), and cable (7) from intake assembly (4). Discard lockwasher (2).
3. Remove pushnut (9) from cable loop (8) and control lever pin (10). Discard pushnut (9).
4. Remove screw (12), lockwasher (13), and cable (7) from control box bracket (11), and disconnect cable
loop (8) from control lever pin (10). Discard lockwasher (13).
b. Evaporator Intake Cable Installation
1. Connect cable loop (8) on control lever pin (10) with pushnut (9).
NOTE
It maybe necessary to adjust turnbuckle on cable to align control
cable clamp with control box bracket.
2. Install cable (7) on control box bracket (11) with lockwasher (13) and screw (12).
3. Connect cable loop (5) on duct door arm (6) with pushnut (3).
4. Install cable (7) on intake assembly (4) with lockwasher (2) and screw (1).
5. Proceed to Cable Adjustment, g. 2.
11-296
TM 9-2320-280-20-3
11-199. DUCT DOOR CONTROL CABLES MAINTENANCE (Cont’d)
11-297
TM 9-2320-280-20-3
11-199. DUCT DOOR CONTROL CABLES MAINTENANCE (Cont’d) I
c. HeaterlAir-Conditioning Outlet Cable Removal

1. Remove two screws (4) and lockwashers (3) from plate (2) and evaporator duct (1). Discard
lockwashers (3).
2. Remove two capscrews (7), lockwashers (8), and plate (2) from evaporator duct (1). Discard
lockwashers (8).
3. Remove screw (6) and lockwasher (9) from cable (10) and evaporator duct (1). Discard lock-
washer (9).
4. Remove pushnut (5) and cable loop (11) from duct door arm (12). Discard pushnut (5).
5. Remove pushnut (23) from cable loop (22) and control lever pin (21). Discard pushnut (23).
6. Remove screw (25) and lockwasher (24) from cable (10) and control box bracket (20), and disconnect
cable loop (22) from control lever pin (21). Discard lockwasher (24).
d. Heater/Air-Conditioning Outlet Cable Installation

1. Connect cable loop (22) on control lever pin (21) with pushnut (23).
NOTE
It maybe necessary to adjust turnbuckle on cable to align control
2. Install cable (10) on control box bracket (20) with lockwasher (24) and screw (25).
3. Install cable (10) on evaporator duct (1) with lockwasher (9) and screw (6).
5. Proceed to Cable Adjustment, g. 3 (c).
e. Heater Intake Cable Removal

1. Remove pushnut (13) and cable loop (14) from duct door arm (15). Discard pushnut (13).
2. Remove screw (19), lockwasher (18), and cable (17) from intake assembly (16). Discard lockwasher (18).
3. Remove pushnut (23) and cable loop (22) from control lever pin (21). Discard pushnut (23).
4. Remove screw (25), lockwasher (24), and cables (10) and (17) from control box bracket (20) and
disconnect cable loop (22) from control lever pin (21). Discard lockwasher (24).
5. Disconnect cable loop (26) from control lever pin (21) and slide cable (17) out from bracket (20).
f. Heater Intake Cable Imtallation

1. Slide cable (17) through bracket (20) and connect cable loop (26) on control lever pin (21).
2. Connect cable loop (22) to control lever pin (21) with pushnut (23).
NOTE
It maybe necessary to adjust turnbuck.le on cable to align control
3. Install cable (10) on control box bracket (20) and install cables (10) and (17) with lockwasher (24)
and screw (25).
5. Install cable (17) on intake assembly (16) with lockwasher (18) and screw (19).
6. Proceed to Cable Adjustment, g. 1.
11-298
TM 9-2320-280-20-3
11-299
TM 9-2320-280-20-3
g. Cable Adjustment
1. Heater intake cable adjustment.

(a) Place top lever (2) on control box (1) in A/C-VENT position.
(b) Adjust turnbuckle (6) on cable (7) until duct door arm (5) is all the way up (duct door fully
2. Evaporator intake cable adjustment.

(a) Place bottom lever (3) on control box (1) in UNIT OFF position.
(b) Adjust tumbuckle (8) on cable (9) until duct door arm (4) is all the way up (duct door fully
3. Heater/air-conditioning outlet cable adjustment.

(a) Remove two screws (13) and lockwashers (12) from plate (11) and evaporator duct (10). Discard
lockwashers (12).
(b) Remove two capscrews (14), lockwashers (15), and plate (11) from evaporator duct (10). Discard
lockwashers (15).
(c) Place top lever (2) on control box (1) in HEAT position.
(d) Adjust turnbuckle (17) on control cable (16) until duct door arm (18) is all the way down (duct
door all the way up).
(e) Place top lever (2) on control box (1) in A/C-VENT position.
(f) Adjust turnbuckle (17) on control cable (16) until duct door arm (18) is all the way up (duct door
all the way down).
(g) Install plate (11) on evaporator duct (10) with two lockwashers (15) and capscrews (14).
(h) Install plate (11) on evaporator duct (10) with two lockwashers (12) and screws (13).
11-300
TM 9-2320-280-20-3
FOLLOW-ON TASKS: . Close blower housing (para. 11-198).

11-301
TM 9-2320-280-20-3
11-200. EVAPORATOR DRAIN TUBE REPLACEMENT

This task covers:
INITIAL SETUP:
M997, M997A1, M997A2 Tiedown strap (Appendix G, Item 241)
Took Manual References
Equipment Condition
Blower housing open (para. 11-198).
NOTE
Perform steps 1 through 3 for old configuration only.
1. Disconnect flex tube (2) from evaporator drain pan (1).
2. Disconnect flex tube (2) from nipple (3).
3. Remove clamp (4) and nipple (3) from drain tube (5).
NOTE
Perform steps 4 through 8 for new configuration only.
4. Remove clamp (10) from drain tube (5).
5. Remove elbow (9) from drain tube (5).
6. Remove clamps (6) and (7) from hose (8).
7. Remove elbow (9) from hose (8).
8. Disconnect hose (8) from evaporator drain pan (1).
9. Remove tiedown strap (12) from harness (13) and drain tube (5). Discard tiedown strap (12).
10. Remove screw (14), clamp (17), and drain tube (5) from body (15).
11. Pull drain tube (5) through cab ceiling grommet (11) and cab floor grommet (16).
b. Intallation
1. Install drain tube (5) through cab floor grommet (16) and cab ceiling grommet (11). Allow
approximately 2 in. (5 cm) of drain tube (5) to extend through cab floor grommet (16).
2. Install drain tube (5) on body (15) with clamp (17) and screw (14).
3. Install drain tube (5) on harness (13) with tiedown strap (12).
NOTE
Perform steps 4 through 6 for new configuration only.
4. Connect hose (8) to evaporator drain pan (1) with clamp (7).
5. Install elbow (9) on hose (8) with clamp (6).
6. Install elbow (9) on drain tube (5) with clamp (10).
NOTE
Perform steps 7 through 9 for old configuration only.
7. Install nipple (3) in drain tube (5) with clamp (4).
8. Connect flex tube (2) to nipple (3).
9. Connect flex tube (2) to evaporator drain pan (1).
11-302
TM 9-2320-280-20-3
11-200. EVAPORATOR DRAIN TUBE REPLACEMENT (Cont’d)
11-303
TM 9-2320-280-20-3
11-201. CONDENSER COOLING FAN REPLACEMENT

This task covers:
INITIAL SETUP:
M997, M997A1, M997A2 TM 9-2320-280-24P
General mechanic’s tool kit: ● Air intake compartment panels removed

● Battery ground cable disconnected (para. 4-73).
Materials/Parts
NOTE
1. Disconnect two harness leads (5) from fan motor leads (6).
2. Remove nut (8), capscrew (2), lockwasher (3), motor clamp (4), and fan motor (11) from bracket (7).
3. Remove rubber mount (12) from fan motor (11).
4. Remove set screw (9) and fan blade (1) from motor shaft (10).
b. Installation
1. Install fan blade (1) on motor shaft (10) with set screw (9).
2. Install rubber mount (12) on fan motor (11).
3. Install fan motor (11) on bracket (7) so that rubber mount (12) is centered on bracket (7), and
further-most comer edges of fan blades (1) are approximately 0.4 in. (10 mm) from fan shroud
facing (13).
4. Install motor clamp (4) to bracket (7) and fan motor (11) with lockwasher (3), capscrew (2), and
nut (8).
5. Connect two harness leads (5) to fan motor leads (6).
11-304
TM 9-2320-280-20-3
11-201. CONDENSER COOLING FAN REPLACEMENT (Cont’d)
FOLLOW-ON TASKS: “ Install air intake compartment panels (para. 11-184).

11-305
TM 9-2320-280-20-3
11-202. COMPRESSOR BELT MAINTENANCE

This task covers:
b. Installation
INITIAL SETUP:
Tools One assistant
Special Tools Equipment Condition
Belt tension gauge (Appendix B, Item 67) ● Engine right splash shield removed (para. 10-20).
Crowfoot, 14 mm (Appendix B, Item 152) ● Engine access cover removed (para. 10-15).
● Serpentine drivebelt removed (“A2” series only)
(para. 3-83).
1. Loosen two capscrews (10) from compressor (11) and support bracket (12).
2. Loosen two nuts (1) and capscrew (7) from adjusting bracket (5) and mounting ears (6).
3. Loosen nut (2) on adjusting bracket (5) and timing cover bolt (3), and push compressor (11) toward
timing chain cover (4) to loosen belt (9).
4. Disconnect fan drive hose (15) from fan drive assembly (17).
5. Remove belt (9) from compressor pulley (8), water pump pulley (14), crankshaft pulley (16), and over
fan blades (13).
b. Installation
Install belt (9) over fan blades (13) and place belt (9) on crankshaft pulley (16), water pump pulley (14),
and compressor pulley (8).
NOTE
If belt was replaced, go to step 2.
1. Perform Removal, steps a.1 through a.4.
CAUTION
DO not pry against compressor housing with pry bar when

adjusting belt tension. Compressor may be damaged.
2. Pull compressor (11) away from timing chain cover (4) and position pry bar between rear mounting
ear (6) and support bracket (12) to adjust belt tension.
3. Using belt tension gauge, check belt (9) for proper tension (refer to table 11-1).
Table 11-1. Compressor Belt Tension Requirements
NOTE
A “used” belt iS one that has run at least fifteen
minutes or fifteen miles (24 kilometers).
11-306
TM 9-2320-280-20-3
1 1 - 2 0 2 . COMPRESSOR BELT MAINTENANCE (Cont'd)
4. If belt (9) tension is correct, tighten nut (2), two capscrews (10), capscrew (7), and two nuts (1).
5. Repeat step (3). If belt (9) tension cannot be properly adjusted, replace belt (9).
6. Tighten nut (2) to 40 lb-ft (54 N•m). Using crowfoot on front capscrew (10), tighten two cap-
screws (10) to 26 lb-ft (35 N•m). Tighten two nuts (1) to 26 lb-ft (35 N•m).
7. Connect fan drive hose (15) to fan drive assembly (17).
FOLLOW-ON TASKS: • Install engine right splash shield (para. 10-20).

• Install engine access cover (para. 10-15).
• Install serpentine drivebelt (A2 series only) (para. 3-83).
Change 1 11-307
TM 9-2320-280-20-3
11-203. AIR-CONDITIONING DUCT LOUVER REPLACEMENT

This task covers:
INITIAL SETUP:

M997, M997A1, M997A2 TM 9-2320-280-24P
Tools
Pry duct louver (2) from air-conditioning duct (1) and remove duct louver (2).
I b. Installation
Push duct louver (2) into opening in air-conditioning duct (1).
11-308
TM 9-2320-280-20-3
11-204. HEATER COMPARTMENT PANEL REPLACEMENT (M996, M996A1)

This task covers:
lNITIAL SETUP:
M996, M996A1 TM 9-2320-280-24P
Tools
a. Removal I
1. Loosen seven wing bolts (1) and remove panel (2) from body (3).
2. Inspect seven retaining washers (4) on wing bolts (1) for presence and damage. Replace retaining
washers (4) if missing or damaged.
Install panel (2) to body (3) with seven wing bolts (1).
11-309
TM 9-2320-280-20-3
11-205. AIR INTAKE FILTER MAINTENANCE

This task covers
Applicable Models
M996, M996A1, M997, M997A1, M997A2 Detergent (Appendix C, Item (17)
Took Equipment Condition

General mechanic’s tool kit: Air intake filters removed (TM 9-2320-280-10).
Manual References . NBC contaminated filters must be handled and
TM 9-2320-280-10 disposed of only by trained personnel.
TM 9-2320-280-24P ● Compressed air used for cleaning purposes will
FM 3-4 not exceed 30 psi (207 kPa).

FM 3-5
WARNING
NBC contaminated filters must be handled and disposed of only by
authorized and trained personnel. The unit commander or senior
officer in charge of maintenance personnel must ensure that
prescribed protective clothing (FM 3-4) is used, and prescribed
safety measures and decontamination procedures (FM 3-5) are
followed. The local unit SOP is responsible for final disposal of
contaminated air filters,
Inspect filters (1) for tears, rips, contaminants, or other damage. Inspect filter frames (2) and supports (3)
for cracks, bends, or other damage. If filters (1), frames (2), or support (3) are damaged, replace.
1. Cleaning with detergent.

Remove oily dirt from filter (1) by gently hand washing in warm water and non-sudsing detergent.
Gently rinse filter (1) with warm water. Allow filter to dry.
2. Cleaning with compressed air.
WARNING
Compressed air used for cleaning purposes will not exceed 30 psi
(207 kPa). Use only with effective chip guarding and personnel
protective equipment (goggles/shield, gloves, etc.).
Remove oily dirt and dust from filter (1) by directing air stream at an angle and approximately 6 in.
(152.4 mm) from filter (1). Blow away loosened dirt or dust from both sides of filter (1).
11-310
TM 9-2320-280-20-3
11-205. AIR INTAKE FILTER MAINTENANCE (Cont’d)
FOLLOW-ON TASK: Install air intake filter (TM 9-2320-280-10).
11-311
TM 9-2320-280-20-3
11-206. HEATER OUTLET/BLOWER FAN HOSE REPLACEMENT (M996, M996A1)

This task covers:
INITIAL SETUP:
M996, M996A1 TM 9-2320-280-24P
Tools Equipment condition
General mechanic’s tool kit: Heater compartment panel removed (para. 11-204).
NOTE
Heater outlet hose and blower fan hose replacement procedures are
basically the same. This procedure covers the heater outlet hose.
Loosen two clamps (3) and remove hose (2) from heater (1) and blower duct (4).
Install hose (2) on blower duct (4) and heater (1) and tighten two clamps (3).
FOLLOW-ON TASK: Install heater compartment panel (para. 11-204).
11-312
TM 9-2320-280-20-3
11-207. HEATER EXHAUST PIPE REPLACEMENT (M996, M996A1)
This task covers:

INITIAL SETUP:
M996, M996A1 TM 9-2320-280-24P
Took General safety Instructions
General mechanic’s tool kit: Do not touch hot exhaust system components with
automotive (Appendix B, Item) bare hands.
Matereials/Parts
WARNING
1. Remove two screws (1) from exhaust pipe bracket (2) and body (7).
2. Remove two capscrews (5) and lockwashers (6) from support bracket (4) and body (7). Discard
lockwashers (6).
3. Remove exhaust pipe (3) and support bracket (4) by sliding out of exhaust outlet (8).
4. Remove two nuts (9), U-bolt (10), clamp (11), and support bracket (4) from exhaust pipe (3).
1. Install support bracket (4) and clamp (11) on exhaust pipe (3) with U-bolt (10) and two nuts (9). Do
not tighten nuts (9).
2. Install exhaust pipe (3) and support bracket (4) on body (7), ensuring end of exhaust pipe (3) is fully
seated on exhaust outlet (8).
3. install exhaust pipe bracket (2) on body (7) with two screws (1).
4. Install support bracket (4) on body (7) with two lockwashers (6) and capscrews (5). Tighten
capscrews (5) to 15 lb-ft (20 N-m).
5. Tighten two nuts (9) to 15 lb-ft (20 Nom).
11-313
TM 9-2320-280-20-3
11-208. HEATER MOUNTING BRACKET ASSEMBLY REPLACEMENT (M996, M996A1)

This task covers:
INITIAL SETUP:
M996, M996A1 TM 9-2320-280-24P
General mechanic’s tool kit Heater removed (para 11-209).
Materials/Parts
NOTE
a. Removal
1. Remove two screws (1), clamps (2), and fuel line (3) from bracket (4).
2. Remove six screws (8) from NBC control box (9) and body (7), and pull control box (9) away for
access.
3. Remove eight rivets (6) and bracket (4) from body (5).
b. Installation
1. Install bracket (4) on body (5) with eight rivets (6).
2. Install fuel line (3) and two clamps (2) on bracket (4) with two screws (1).
3. Install NBC control box (9) on body (7) with six screws (8).
11-314
TM 9-2320-280-20-3
11-208. HEATER MOUNTING BRACKET ASSEMBLY REPLACEMENT (M996, M996A1) (Cont’d)
FOLLOW-ON TASK: Install heater (para. 11-209).

TM 9-2320-280-20-3
11-209. HEATER REPLACEMENT (M996, M996A1)

This task covers:
lNITIAL SETUP:
M996, M996A1 TM 9-2320-280-24P
General mechanic’s tool kit: ● Blower assembly removed (para. 11-212).
automotive (Appendix B, Item 1) . Heater outlet hose removed (para. 11-206).

Sealing compound (Appendix C, Item 44) Do not perform this procedure near fire, flames, or
Two screw-assembled lockwashers sparks.
Personnel Required
One mechanic
One assistant
WARNING
NOTE
. Have drainage container ready to catch fuel.
● Cover or plug all open connections immediately after

● Apply sealing compound to threads of all fuel line joints before
installation.
a. Removal
1. Disconnect fuel line (11) from heater (2) and allow fuel to drain.
2. Disconnect control box plug (7) from heater receptacle (1).
3. Remove two clamps (9) and heater (2) from mounting brackets (10).
4. Remove four screws (8) and outlet (5) from heater (2).
5. Remove two screw-assembled lockwashers (6), exhaust tube (4), and seal (3) from heater (2). Discard
screw-assembled lockwashers (6).
6. Inspect seal (3) for damage, replace if damaged.
1. Install seal (3) and exhaust tube (4) on heater (2) with two screw-assembled lockwashers (6).
2. Install outlet (5) on heater (2) with four screws (8).
3. Install two clamps (9) on mounting brackets (10).
NOTE
Have assistant guide exhaust outlet into exhaust pipe from outside of
vehicle. Install heater exhaust outlet in first for proper clearance.
4. Install heater (2) on mounting brackets (10) with clamps (9).
11-316
TM 9-2320-280-20-3
11-209. HEATER REPLACEMENT (M996, M996A1) (Cont’d)

6. Connect control box plug (7) to heater receptacle (1).
FOLLOW-ON TASKS: ● Install heater outlet hose (para. 11-206).

. Install blower assembly (para. 11-212).
11-317
TM 9-2320-280-20-3
11-210. BLOWER OUTLET DEFLECTOR REPLACEMENT

This task covers:
INITIAL SETUP:
M996, M996A1 Nineteen rivets (Appendix G, Item 189)
NOTE
a. Removal
1. Remove two rivets (3) from deflector (1) and bracket (4).
2. Remove seventeen rivets (5) and deflector (1) from body (2).
1. Install deflector (1) on body (2) with seventeen rivets (5).

2. Install deflector (1) on bracket (4) with two rivets (3).
11-318
TM 9-2320-280-20-3
11-211. HEAT/AIR-CONDITIONING DUCT MAINTENANCE

This task covers:
INITIAL SETUP:
M997, M997A1, M997A2 TM 9-2320-280-24P
General mechanic’s tool kit: ● Control box assembly removed (para. 4-96).
automotive (Appendix B, Item 1) ● Upper and lower stowage doors removed
(para. 11-152).
Materials/Parts . NBC heater bracket removed (para. 11-165).
Thirty-six rivets (Appendix G, Item 189)
Twelve rivets (Appendix G, Item 195)
NOTE
1. Remove two screws (8), clamps (3), and light harness (18) from duct (17).
2. Remove eight rivets (7) and three stowage shelves (6) from duct (17).
3. Remove twenty rivets (9) from duct (17) and body (4).
4. Remove eight screws (14) and floor duct (13) from duct (17) and floor tunnel (11).
5. Remove eight rivets (1) and duct (17) from air-conditioning outlet (2).
b. Disassembly
1. Remove six rivets (12), washers (15), and guard (5) from duct (17).
2. Remove six rivets (10) and three reinforcement plates (16) from duct (17).
11-319
TM 9-2320-280-20-3
11-211. HEAT/AIR-CONDITIONING DUCT MAINTENANCE (Cont’d)
1. Install three reinforcement plates (16) on duct (17) with six rivets (10).
2. Install guard (5) on duct (17) with six washers (15) and rivets (12).
d.hmal.lation
1. Install duct (17) on air-conditioning outlet (2) with eight rivets (1).
2. Install floor duct (13) on duct (17) and floor tunnel (11) with eight screws (14).
3. Install duct (17) on body (4) with twenty rivets (9).
4. Install three stowage shelves (6) on duct (17) with eight rivets (7).
5. Install two clamps (3) and light harness (18) on duct (17) with two screws (8).
FOLLOW-ON TASKS: . Install NBC heater bracket (para. 11-165).

. Install upper and lower stowage doors (para. 11-152).
. Install control box assembly (para. 4-96).
11-320
TM 9-2320-280-20-3
11-212. BLOWER ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
M996, M996A1 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) ● Battery ground cable disconnected (para. 4-73).
s Heater compartment panel removed

Four nut and lockwasher assemblies
NOTE
1. Loosen two clamps (5) and disconnect hose ducts (2) from diverter box (8).
2. Remove pushnut (3) and disconnect control linkage (4) from diverter box arm (17). Discard
pushnut (3).
NOTE
Prior to removal tag leads for installation,
3. Disconnect harness leads 770 (12), 771 (13), and 772 (14) from blower motor leads (11).
4. Remove four nut and lockwasher assemblies (10), capscrews (6), washers (7), harness clamp (9), two
ground terminals (15), and blower assembly (1) from bracket (16). Discard nut and lockwasher
assemblies (10).
11-321
TM 9-2320-280-20-3
11-212. BLOWER ASSEMBLY REPLACEMENT (Cont’d)
Remove four rivets (20), diverter box (9), and foot (19) from blower assembly (1).
1. Install diverter box (9) and foot (19) on blower assembly (1) with four rivets (20).
2. Install blower assembly (1), harness clamp (10), and two ground terminals (16) on bracket (17) with
four washers (8), capscrews (7), and nut and lockwasher assemblies (11).
3. Connect leads 770 (13), 771 (14), and 772 (15) to blower motor leads (12).
4. Place lever on heat/vent control panel in UNIT OFF position (TM 9-2320-280-10). Turn adjustable
end (3) of control linkage (5) so that diverter box arm (18) is installed all the way forward
(toward blower motor) when adjustable end (3) iS installed on diverter box arm (18).
5. Install control linkage (5) on diverter box arm (18) with pushnut (4).
6. Install two hose ducts (2) on diverter box (9) and tighten clamps (6).
FOLLOW-ON TASKS: . Install heater compartment panel (para. 11-204).

● Check blower for proper operation (TM 9-2320-280-10).
11-322
TM 9-2320-280-20-3
11-213. AIR DIVERTER REPLACEMENT (M996, M996A1)

This task covers:
lNITIAL SETUP:
M996, M996A1 TM 9-2320-280-24P
General mechanic’s tool kit: Blower assembly removed (para. 11-212).
Materials/Parts
Nine rivets (Appendix G, Item 189)
NOTE
1. Remove pushnut (4) and control linkage (5) from diverter door arm (6). Discard pushnut (4).
2. Remove nine rivets (1) and diverter (3) from body (2),
b. Installation
1. Install diverter (3) on body (2) with nine rivets (1).
2. Connect control linkage (5) on diverter door arm (6) with pushnut (4).
FOLLOW-ON TASK: Install blower assembly (para. 11-212).
11-323
TM 9-2320-280-20-3
11-214. PANEL INSULATION REPLACEMENT

This task covers:
lNITIAL SETUP:
M997, M997A1 M997A2 TM 9-2320-280-24P
Equipment Condition
General mechanic’s tool kit: Blower housing opened (para. 11-198).
NOTE
Replacement of all air-conditioning insulation panels is basically
the same. This procedure covers the air intake compartment
insulation panel.
Remove insulation (3) from air intake compartment panel (1). Clean panel (1) to remove remaining
adhesive.
Peel paper backing (2) from insulation (3) and install insulation (3) on air intake compartment panel (1).
11-324
TM 9-2320-280-20-3
I 11-215. AMBULANCE SPREADER BAR MAINTENANCE

This task covers:
INITIAL SETUP:
M996, M996A1, M997, M997A1, M997A2 TM 9-2320-280-24P

1. Remove three pins (3) and extension bar (1) from ambulance.
2. Remove two links (7) from extension bar (1).
b. Disassembly
1. Remove six ferrules (2) and three cables (4) from extension bar (1) and three pins (3).
2. Disconnect two cable assemblies (6) from links (7).
3. Disconnect two snap hooks (5) from cable assemblies (6).
c. Assembly
1. Connect two snap hooks (5) to cable assemblies (6).
2. Connect two cable assemblies (6) to links (7).
3. Install six ferrules (2) and three cables (4) on extension bar (1) and three pins (3).
1. Install two links (7) on extension bar (1).

2. Install extension bar (1) on ambulance with three pins (3).
11-325/(11-326 blank)
TM 9-2320-280-20-3
CHAPTER 12
SPECIAL PURPOSE KITS MAINTENANCE
Section I. DEEP WATER FORDING KIT MAINTENANCE
1 2 - 1 . DEEP WATER FORDING KIT MAINTENANCE TASK SUMMARY
TA S K PA G E
PROCEDURES
PA R A . NO.
12-2. Deep Water Fording Kit Exhaust Assembly Maintenance 12-2

12-3. Deep Water Fording Kit Air Intake Assembly Replacement 12-4
12-4. Air Cleaner Extension Elbow Maintenance 12-5
12-5. Windshield Mounting Bracket Replacement 12-7
12-6. Air Cleaner Dust Cap Maintenance 12-8
12-7. Air Cleaner to Selector Valve Vent Line Replacement 12-9
12-8. Fuel Tank Vent Stack Tube Replacement 12-10
12-9. Selector Valve Replacement 12-11
12-10. CDR Valve Vent Line Replacement 12-13
12-11. Hydro-Boost Vent Line Replacement 12-14
12-12. Deep Water Fording Sensor Cup Replacement 12-15
12-13. Sensor Cup Vent Line Replacement 12-16
12-14. Power Steering Vent Line Replacement 12-17
12-15. Exhaust Reinforcement Bracket Replacement 12-18
Change 1 12-1
TM 9-2320-280-20-3
12-2. DEEP WATER FORDING KIT EXHAUST ASSEMBLY MAINTENANCE

This task covers:
b.Inspection
INITIAL SETUP
M1025A1, M1025A2, M1026, M1026A1 TM 9-2320-280-24P
General mechanic’s tool kit: Do not touch hot exhaust system components with
automotive (Appendix B, Item 1) bare hands.
Materials/Parts
WARNING
1. Remove three locknuts (1), washers (2), capscrews (10), washers (2), exhaust assembly (9), and
gasket (11) from muffler (3). Discard locknuts (1) and gasket (11).
2. Remove two locknuts (4), washers (5), exhaust assembly (9), and two spacers (8) from wheel
house (7). Discard locknuts (4).
NOTE
Perform steps 3 through 5 for M997, M997A1, and M997A2 models only.
3. Remove two bolts (18), washers (16), and exhaust extension (17) from upper body (25).
4. Remove locknut (19), washer (20), noise damper (21), exhaust reinforcement bracket (24),
isolator (22), noise damper (23), and bolt (13) from exhaust extension (17). Discard locknut (19).
5. Remove two isolators (15) and spacers (14) from bracket (24).
1. Inspect two insulators (6) for breaks, cracks, or deterioration. Replace if damaged.
NOTE
Perform step 2 for M997, M997A1, and M997A2 models only.
2. Inspect two rivnuts (12) for thread damage or deterioration. Replace if damaged.
12-2
TM 9-2320-280-20-3
12-2. DEEP WATER FORDING KIT EXHAUST ASSEMBLY MAINTENANCE (Cont’d)
c. Installation
NOTE
Perform steps 1 through 3 for M997, M997A1, and M997A2
models only.
1. Install two spacers (14) and isolators (15) on bracket (24).
2. Install bolt (13), bracket (24), isolator (22), and noise damper (23) on exhaust extension (17) with
noise damper (21), washer (20), and locknut (19). Tighten locknut (19) to 17 lb-ft (23 N=m).
3. Install exhaust extension (17) on upper body (25) with two washers (16) and bolts (18).
4. Install two spacers (8) and exhaust assembly (9) on wheelhouse (7) with two washers (5) and
5. Install exhaust assembly (9) and gasket (11) on muffler (3) with three washers (2), capscrews (10),
FOLLOW-ON TASK: Start engine (TM 9-2320-280-10) and check for exhaust leaks.
12-3
TM 9-2320-280-20-3
12-3. DEEP WATER FORDING KIT AIR INTAKE ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
M1025A1, M1025A2, M1026, M1026A1
Equipment Condition
Tools ● Weathercap removed (para. 3-18).
General mechanic’s tool kit: ● Fuel tank vent stack tube removed (para. 12-8).

Materials/Parts
1. Remove locknut (5), washer (3), capscrew (2), and washer (3) from air intake assembly (1) and
windshield mounting bracket (4). Discard locknut (5).
2. Loosen clamp (6) and remove air intake assembly (1) from air cleaner extension elbow (7).
b. Installation
1. Install air intake assembly (1) into air cleaner extension elbow (7) with clamp (6). Tighten clamp (6)
to 45-50 lb-in. (5-6 N.m).
2. Install air intake assembly (1) on windshield mounting bracket (4) with washer (3), capscrew (2),
washer (3), and locknut (5). Tighten capscrew (2) to 43 lb-ft (58 N.m).
FOLLOW-ON-TASKS: ● Install weather cap (para. 3-18).

. Install fuel tank vent stack tube (para. 12-8).
12-4
TM 9-2320-280-20-3
12-4. AIR CLEANER EXTENSION ELBOW MAINTENANCE

This task covers:
b. Inspection
INITIAL SETUP:
M1025A1, M1025A2, M1026, M1026A1
Equipment Condition
Tools Deep water fording kit removed (para. 12-3).
1. Loosen clamp (3) and disconnect air horn-to-air cleaner elbow (4) from air cleaner assembly (6).
2. Disconnect air cleaner-to-selector valve vent line (2) from air cleaner assembly (6).
3. Disconnect air restriction gauge hose (5) from air cleaner assembly (6).
4. Loosen two outer clamps (7) from air cleaner assembly (6) and support brackets (11).
5. Remove air cleaner assembly (6), gasket (8), and air cleaner extension elbow (10) from air induction
box (1).
6. Loosen clamp (9) and remove air cleaner extension elbow (10) from air cleaner assembly (6).
12-5
TM 9-2320-280-20-3
12-4. AIR CLEANER EXTENSION ELBOW MAINTENANCE (Cont’d)
b. Inspection
Inspect gasket (8) for breaks or cracks. Replace if broken or cracked.
1. Install air cleaner extension elbow (10) on air cleaner assembly (6). Tighten clamp (9) to 45-50 lb-in.
(5-6 N.m).
2. Install air cleaner extension elbow (10) on air induction box (1),
3. Install air cleaner assembly (6) on support brackets (11) with two outer clamps (7). Tighten
clamps (7) to 35-40 lb-in. (4-5 N.m).
4. Connect air restriction gauge hose (5) to air cleaner assembly (6).
5. Connect air cleaner-to-selector valve vent line (2) to air cleaner assembly (6).
6. Connect air horn-to-air cleaner elbow (4) to air cleaner assembly (6). Tighten clamp (3) to 45-50 lb-
in. (5-6 N=m).
FOLLOW-ON TASK: Install air intake assembly (para. 12-3).
12-6
TM 9-2320-280-20-3
1 2 - 5 . WINDSHIELD MOUNTING BRACKET REPLACEMENT
This task covers:

INITIAL SETUP:
M1025A1, M1025A2, M1026, M1026A1,
M1121 Equipment Condition
Deep water fording kit removed (para. 12-3).
Tools
a. Removal
Remove two capscrews (1), washers (2), and windshield mounting bracket (3) from windshield (4).
b. Installation
Install windshield mounting bracket (3) on windshield (4) with two washers (2) and capscrews (1).
Tighten capscrews (1) to 6 lb-ft (8 N•m).
Change 1 12-7
TM 9-2320-280-20-3
1 2 - 6 . AIR CLEANER DUST CAP MAINTENANCE

This task covers:
b. Inspection
INITIAL SETUP:
M1025A1, M1025A2, M1026, M1026A1, TM 9-2320-280-24P
M1121
Equipment Condition
a. Removal
1. Remove four screws (5) and dust unloader cover plate (4) from air cleaner bracket (6).
2. Remove clamp (2) and air cleaner dust cap (3) from air cleaner assembly (1).
b. Inspection
Inspect air cleaner dust cap (3) for cuts, tears, obstructions, or enlarged gap. Replace if cut, torn, worn,
missing, or if center opening exceeds 0.125 in. (3.18 mm).
c. Installation
1. Install dust cap (3) on air cleaner assembly (1) with clamp (2). Tighten clamp (2) to 45-50 lb-in.
(5-6 N•m).
2. Install dust unloader cover plate (4) on air cleaner bracket (6) with four screws (5).
12-8 Change 1
TM 9-2320-280-20-3
12-7. AIR CLEANER TO SELECTOR VALVE VENT LINE REPLACEMENT

1
This task covers:
INITIAL SETUP:
M1025A1, M1025A2, M1026, M1026A1 TM 9-2320-280-24P
Tools .
Equipment Condition
Materoa;s/Parts
Three tiedown straps (Appendix G, Item 241)
a. Removal
1. Disconnect air cleaner-to-selector valve vent line (2) from air cleaner assembly fitting (1).
2. Remove three tiedown straps (3) and vent line (2) from existing hoses (4) on “A” beam (5).
Discard tiedown straps (3).
3. Remove air cleaner-to-selector valve vent line (2) from selector valve (6).
b. Installation
1. Connect air cleaner-to-selector valve vent line (2) to selector valve (6).
2. Route vent line (2) along “A” beam (5) and secure to existing hoses (4) with three tiedown straps (3).
3. Connect air cleaner-to-selector vent line (2) to air cleaner assembly fitting (1).
12-9
TM 9-2320-280-20-3
12-8. FUEL TANK VENT STACK TUBE REPLACEMENT

This task covers:
INITIAL SETUP:
M1025A1, M1025A2, M1026, M1026A1, TM 9-2320-280-24P
M1097, M1097A1, M1097A2
Equipment Condition
Materials/Parts
1. Disconnect fuel tank vent line (8) from fuel tank vent stack tube (2).
2. Remove nut (10), lockwasher (9), screw (7), and clamp (6) from fuel tank vent stack tube (2) and air
intake assembly (1). Discard lockwasher (9).
3. Remove screw (5), lockwasher (4), fuel tank vent stack tube (2), and clamp (3) from air intake
assembly (1). Discard lockwasher (4).
b. Installation
1. Install fuel tank vent stack tube (2) and clamp (3) on air intake assembly (1) with lockwasher (4)
and screw (5).
2. Install fuel tank vent stack tube (2) and clamp (6) on air intake assembly (1) with lockwasher (9),
screw (7), and nut (10).
3. Connect vent line (8) to vent stack tube (2).
12-10
TM 9-2320-280-20-3
12-9. SELECTOR VALVE REPLACEMENT

This task covers:
INITIAL SETUP
M1025A1, M1025A2, M1026, M1026A1, TM 9-2320-280-24P
M1097, M1097A1, M1097A2-
Equipment Condition
Tools . Hood raised and secured (TM 9-2320-280-10).
General mechanic’s tool kit: . Engine access cover removed (para. 10-15).
Materials/Parts
a. Removal
1. Remove screw (1) and selector control (2) from selector valve (4).
2. Remove two locknuts (9), washers (13), capscrews (14), and washers (13) from selector valve (4) and
NOTE
Prior to removal, tag vent lines for installation.
3. Disconnect air cleaner-to-selector valve vent line (6) from elbow (5).
4. Disconnect selector valve-to-union tee vent line (8) from connector (7).
5. Loosen clamp (11) and disconnect CDR valve vent line (10) from elbow (12).
6. Remove elbow (5), connector (7), and elbow (12) from selector valve (4).
12-11
TM 9-2320-280-20-3
12-9. SELECTOR VALVE REPLACEMENT (Cont’d)
b. Installation
1. Install elbow (12), connector (7), and elbow (5) on selector valve (4).
2. Connect CDR valve vent line (10) to selector elbow (12) with clamp (11).
3. Connect selector valve-to-union tee vent line (8) to connector (7).
4. Connect air cleaner-to-selector valve vent line (6) to elbow (5).
5. Install selector valve (4) on body (3) with two washers (13), capscrews (14), washers (13), and
6. Install selector control (2) on selector valve (4) with screw (1).
FOLLOW-ON TASKS: ● Install engine access cover (para. 10-15).

. Lower and secure hood (TM 9-2320-280-10).
12-12
TM 9-2320-280-20-3
12-10. CDR VALVE VENT LINE REPLACEMENT

This task covers:
INITIAL SETUP:
M1025A1, M1025A2, M1026, M1026A1, TM 9-2320-280-24P
M1097, M1097A1, M1097A2
Equipment Condition
Materials/Parts
‘IWO tiedown straps (Appendix G, Item 241)
1. Loosen clamp (2) and disconnect CDR valve vent line (3) from CDR valve (1).
2. Remove two tiedown straps (5) from vent line (3) and existing hoses (6) on “A” beam (4).
Discard tiedown straps (5).
3. Loosen clamp (2) and remove vent line (3) from elbow (8) on selector valve (7).
4. Remove clamps (2) from vent line (3).
b. Installation
1. Install clamps (2) on vent line (3).

2. Connect vent line (3) to elbow (8) on selector valve (7) with clamp (2).
3. Install vent line (3) along “A” beam (4) on existing hoses (6) with two tiedown straps (5).
4. Connect vent line (3) to CDR valve (1) with clamp (2).
12-13
TM 9-2320-280-20-3
12-11. HYDRO-BOOST VENT LINE REPLACEMENT

This task covers:
INITIAL SETUP:
M1025A1, M1025A2, M1026, M1026A1,
M1097, M1097A1, M1097A2 Equipment Condition
Engine left splash shield removed (para. 10-17).
Tools
Materials/Parts
1. Disconnect hydro-boost vent line (2) from hydro-boost (1).

2. Remove nut and lockwasher assembly (3), capscrew (10), clamp (4), harness clamp (9), and vent
line (2) from body (11). Discard nut and lockwasher assembly (3).
3. Remove locknut (6), washer (7), capscrew (8), washer (7), clamp (5), and vent line (2) from body (11).
4. Remove two clamps (4) and (5) from vent line (2).
b. Installation
1. Install two clamps (4) and (5) on vent line (2).
2. Install vent line (2) and clamp (5) on body (11) with washer (7), capscrew (8), washer (7), and
locknut (6). Tighten capscrew (8) to 6 lb-ft (8 Nom).
3. Install vent line (2), harness clamp (9), and clamp (4) on body (11) with capscrew (10), and nut and
4. Connect vent line (2) to hydro-boost (1).
FOLLOW-ON TASK: Install engine left splash shield (para. 10-17).
12-14
TM 9-2320-280-20-3
12-12. DEEP WATER FORDING SENSOR CUP REPLACEMENT I

This task covers:
lNITIAL SETUP:
M1025A1, M1025A2, M1026, M1026A1
Equipment Condition
Tools Engine access cover removed (para. 10-15).
Materials/Parts
1. Loosen clamp (3) and disconnect sensor cup vent line (2) from sensor cup (4).
2. Remove two locknuts (1), washers (6), capscrews (5), washers (6), and sensor cup (4) from
1. Install sensor cup (4) on body (7) with two washers (6), capscrews (5), washers (6), and locknuts (1).
2. Connect sensor cup vent line (2) to sensor cup (4) with clamp (3).
FOLLOW-ON TASK: Install engine access cover (para. 10-15).
12-15
TM 9-2320-280-20-3
12-13. SENSOR CUP VENT LINE REPLACEMENT

This task covers:
INITIAL SETUP:
General mechanic’s tol kit: ● Hood raised and secured (TM 9-2320-280-10).
automotive (Appendix B, Item 1) ● Egine access cover removed (paa. 10-15).
Manual References
TM 9-2320-280-10
TM 9-2320-20-24P
1. Loosen clamp (3) and disconnect sensor cup vent line (1) from CDR valve (2).
2. Loosen clamp (6) and remove vent line (1) from sensor cup (5).
3. Remove two clamps (3) and (6) from vent line (1).
1. Install two clamps (3) and (6) on vent line (1).

2. Route vent line (1) through “A” beam (4).
3. Connect vent line (1) to sensor cup (5) with clamp (6).
4. Connect vent line (1) to CDR valve (2) with clamp (3).
FOLLOW-ON TASKS: . Install engine access cover (para. 10-15).

. Lower and secure hood (TM 9-2320-280-10).
12-16
TM 9-2320-280-20-3
12-14. POWER STEERING VENT LINE REPLACEMENT

This task covers:
INITIAL SETUP:
M1025A1, M1025A2, M1026, M1026A1, TM 9-2320-280-24P
M1097, M1097A1, M1097A2
Equipment Condition
a. Removal
Remove power steering vent line (1) from power steering pump cap (3) and tee fitting (2).
Connect vent line (1) to power steering cap (3) and tee fitting (2).
12-17
TM 9-2320-280-20-3
12-15. EXHAUST REINFORCEMENT BRACKET REPLACEMENT

This task covers:
lNITIAL SETUP:
Equipment Condition
Materials/Parts Deep water fording kit exhaust assembly removed
Eight locknuts (Appendix G, Item 58) (para. 12-2).
a. Removal
1. Remove two isolators (4) from wheelhouse (3) and reinforcement bracket (5).
2. Remove eight locknuts (6), washers (1), capscrews (2), washers (1), and reinforcement bracket (5)
from wheelhouse (3). Discard locknuts (6).
1. Install reinforcement bracket (5) on wheelhouse (3) with eight washers (1), capscrews (2),
washers (1), and locknuts (6). Tighten capscrews (2) to 6 lb-ft (8 Win).
2. Install two isolators (4) on wheelhouse (3) and reinforcement bracket (5).
FOLLOW-ON TASK: Install deep water fording kit exhaust assembly (para. 12-2).
12-18
TM 9-2320-280-20-3
Section II. TROOP SEAT KIT MAINTENANCE
12-16. TROOP SEAT KIT MAINTENANCE TASK SUMMARY
TASK PAGE
PROCEDURES
PARA. NO.
12-17. Seat Support Replacement 12-19

12-18. Troop Seat Kit Replacement 12-20
12-19. Troop Seat Board Replacement 12-22
12-17. SEAT SUPPORT REPLACEMENT

This task covers:
lNITIAL SETUP:
M998, M998A1, M1038, M1038A1, M1097, Three cotter pins (Appendix G, Item 26)
M1097A1, M1097A2
Manual References
Tools TM 9-2320-280-24P
1. Remove two lockpins (1) from troop seat (2).

2. Lower seat support (4).
3. Remove three cotter pins (6), clevis pins (5), and seat support (4) from back support (3). Discard
cotter pins (6).
1. Install seat support (4) on back support (3) with three clevis pine (5) and cotter pins (6).
2. Raise seat support (4) and install two lockpins (1) on troop seat (2).
12-19
TM 9-2320-280-20-3
12-18. TROOP SEAT KIT REPLACEMENT

This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1, M1097, One mechanic
M1097A1, M1097A2 One assistant
Materials/Parts
Ten locknuts (Appendix G, Item 76)
1. Remove three locknuts (16), washers (2), capscrews (3), washers (2), and rear angle
bracket (18) from wheelhouse (1). Discard locknuts (16).
2. Remove two locknuts (13), washers (14), capscrews (17), washers (14), and rear bracket retainer
plate (15) from wheelhouse (1). Discard locknuts (13).
3. Remove two nuts (9), washers (7), capscrews (8), washers (7), and support bracket (6)
from wheelhouse (1).
4. Remove six locknuts (12), washers (5), capscrews (4), washers (5), three reinforcement
plates (11), and main channel (10) from wheelhouse (1). Discard locknuts (12).
5. Remove troop seat (19).
6. Remove three locknuts (22), washers (21), capscrews (24), and channel support (23) from
“B” pillar (20). Discard locknuts (22).
1. Install channel support (23) on “B” pillar (20) with three capscrews (24), washers (21), and
locknuts (22), Tighten locknuts (22) to 15 lb-ft (20 N.m).
2. Install troop seat (19) on wheelhouse (1).
3. Install main channel (10) and three reinforcement plates (11) on wheelhouse (1) with six washers (5),
capscrews (4), washers (5), and locknuts (12), Tighten capscrews (4) to 15 lb-ft (20 N.m).
4. Install support bracket (6) on wheelhouse (1) with two washers (7), capscrews (8), washers (7), and
nuts (9). Tighten nuts (9) to 43 lb-ft (58 N.m).
5. Install rear bracket retainer plate (15) on wheelhouse (1) with two washers (14), capscrews (17),
6. Install rear angle bracket (18) on wheelhouse (1) with three washers (2), capscrews (3), washers (2),
12-20
TM 9-2320-280-20-3
12-18. TROOP SEAT KIT REPLACEMENT (Cont’d)
12-21
TM 9-2320-280-20-3
12-19. TROOP SEAT BOARD REPLACEMENT

This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1, M1097, Three nut and lockwasher assemblies
M1097A1, M1097A2 (Appendix G, Item 146)
NOTE
The procedure for replacing seat boards and back boards is
basically the same. This procedure covers seat boards.
Remove three carriage bolts (1), nut and lockwasher assemblies (3), and seat board (2) from channel
assembly (4). Discard nut and lockwaaher assemblies (3).
Install seat board (2) on channel assembly (4) with three carnage bolts (1) and nut and lockwasher
assemblies (3).
12-22
TM 9-2320-280-20-3
Section III. 100 AMPERE ALT E R N ATOR KIT MAINTENANCE
1 2 - 2 0 . 100 AMPERE ALT E R N ATOR MAINTENANCE TASK SUMMARY
TA S K PA G E
PROCEDURES
PA R A . NO.
12-21. 100 Ampere Regulator (R027096300) Replacement 12-24

12-22. 100 Ampere Regulator (12342944, N3106) Replacement 12-28
12-22.1. 100 Ampere Alternator Cable (12446821-2) Replacement 12-28.2
12-23. 100 Ampere Alternator (12340912) Replacement 12-30
12-24. 100 Ampere Alternator (12342944) Replacement 12-32
12-24.1. 100/200 Ampere Dual Voltage 12-34.2
Alternator and Regulator Conversion
Change 1 12-23
TM 9-2320-280-20-3
1 2 - 2 1 . 100 AMPERE REGULATOR (R027096300) REPLACEMENT
This task covers:

INITIAL SETUP:
M1026A1, M1097, M1097A1, M1097A2, TM 9-2320-280-24P
M1123
Equipment Condition
Tools • Battery ground cable disconnected (para. 4-73).
General mechanic’s tool kit: • Hood raised and secured (TM 9-2320-280-10).
Materials/Parts
Antiseize compound (Appendix C, Item 13)
Silicone (Appendix C, Item 48)
Ten lockwashers (Appendix G, Item 108)
NOT E
• Prior to removal, tag leads for installation.
• Older model regulators have two screws securing regulator
cover and terminals are sealed with sealant. Newer model
regulators have four screws securing regulator cover and no
sealant. Identify which type is on vehicle and follow particular
model steps as noted.
a. Removal
1. Remove capscrew (11), lockwasher (10), and lead 3B (8) from regulator (9). Discard
lockwasher (10).
NOT E
Perform steps 2 and 3 for older model regulators and step 4 for
newer models.
2. Remove two screws (3), lockwashers (2), and cover (1) from regulator (9). Discard lockwashers (2).
3. Remove sealant from cover (1), leads (4), (5), and (7), and regulator (9).
4. Remove four screws (3), lockwashers (2), cover (18), gasket (17) and sealing wedge (16) from
regulator (9) and leads (4), (5), and (7). Discard lockwashers (2).
5. Remove nut (13), lockwasher (12), and lead 5A (4) from regulator (9). Discard lockwasher (12).
6. Remove nut (15), lockwasher (14), and lead 2A (5) from regulator (9). Discard lockwasher (14).
7. Disconnect regulator lead 568 (7) from engine harness lead 568A (6).
8. Loosen two clamp nuts (23) and remove clamp pins (22) and guard (21) from regulator slots (19).
9. Unscrew connector plug (24) and remove regulator (9) from alternator (20).
12-24 Change 1
TM 9-2320-280-20-3
12-21. 100 AMPERE REGULATOR (R027096300) REPLACEMENT (Cont’d)
12-25
TM 9-2320-280-20-3
1 2 - 2 1 . 100 AMPERE REGULATOR (R027096300) REPLACEMENT( C o n t ’ d )
b. Installation
1. Fill alternator receptacle (8) with silicone. Install regulator (1) on alternator (3) and tighten
connector plug (9) between alternator (3) and regulator (1).
2. Ensure guard (4) is positioned in rear clamp (5). Install clamp pins (7) into regulator slots (2).
Tighten two clamp nuts (6) to 35-45 lb-in. (4-5 N•m).
NOT E
Ensure terminals are clean before connections are made.
3. Connect engine harness lead 568A (15) to regulator lead 568 (16).
4. Connect lead 2A (14) to regulator (1) with lockwasher (23) and nut (24). Tighten nut (24) to 20 lb-in.
(2.3 N•m).
5. Connect lead 5A (13) to regulator (1) with lockwasher (21) and nut (22). Tighten nut (22) to 50 lb-in.
(5.6 N•m).
NOT E
Perform steps 6 and 7 for older model regulators, and steps 8
and 9 for newer model regulators.
6. Completely fill regulator cavity (18) with sealant to form a water tight seal. Sealant should extrude
from side of cover (10) when installed.
7. Install cover (10) to regulator (1) and secure with two lockwashers (11) and screws (12).
8. Insert leads (13), (14), and (17) into sealing wedge (29) and install sealing wedge (29) in regulator
cavity (18).
9. Install gasket (25) and cover (26) on regulator (1) with four lockwashers (28) and screws (27).
10. Apply antiseize compound to contact surface of lead 3B (17). Install lead 3B (17) on regulator (1)
with lockwasher (19) and capscrew (20). Tighten capscrew (20) to 90 lb-in. (10 N•m).
12-26 Change 1
TM 9-2320-280-20-3
12-21. 100 AMPERE REGULATOR (R027096300) REPLACEMENT (Cont’d)
FOLLOW-ON TASKS: Ž Lower and secure hood (TM 9-2320-280-10).

• Connect battery ground cable (para. 4-73).
Ž Start engine (TM 9-2320-280-10) and observe voltmeter for proper reading.
12-27
TM 9-2320-280-20-3
1 2 - 2 2 . 100 AMPERE REGULATOR (12342944, N3106) REPLACEMENT

This task covers:
INITIAL SETUP:
M1026A1, M1097, M1097A1, M1097A2, M1123 TM 9-2320-280-24P
General mechanic’s tool kit: • Battery ground cables disconnected (para. 4-73).
automotive (Appendix B, Item 1) • Hood raised and secured (TM 9-2320-280-10).
Materials/Parts
a. Removal
NOT E
1. Disconnect regulator plug (1) from voltage regulator (4).
2. Slide back rubber boot (21) and remove nut (22), lead 5A (23), and washer (24) from red (energize)
terminal (25).
3. Slide back rubber boot (18) and remove nut (17), lead 2A (16), and washer (15) from yellow (AC)
terminal (14).
NOT E
Perform steps 4 and 5 for M1025A2, M1035A2, M1043A2, and
M1045A2 vehicles only.
4. Slide back rubber boot (12) and remove nut (11), lead (10), and washer (9) from terminal (8).
5. Disconnect regulator connector (20) from alternator connector (19).
6. Remove two screws (5), lockwashers (6), and washers (7) securing voltage regulator (4) to
alternator (13). Discard lockwashers (6).
7. Remove capscrew (3), lockwasher (2), and voltage regulator (4) from alternator (13). Discard
lockwasher (2).
b. Installation
1. Apply sealing compound to threads of capscrew (3).

2. Install voltage regulator (4) on alternator (13) with lockwasher (2) and capscrew (3). Tighten
capscrew (3) to 88-94 lb-in. (10-11 N•m).
3. Install two washers (7), lockwashers (6), and screws (5) on voltage regulator (4) and alternator (13).
Tighten screws (5) to 30-34 lb-in. (3-4 N•m).
NOT E
Perform steps 4 and 5 for M1025A2, M1035A2, M1043A2, and
M1045A2 vehicles only.
4. Install washer (9), lead (10), and nut (11) on terminal (8). Tighten nut (11) to 18-22 lb-in.
(2.0-2.5 N•m). Slide rubber boot (12) over terminal (8).
5. Connect regulator connector (20) to alternator connector (19).
6. Install washer (24), lead 5A (23), and nut (22) on red (energize) terminal (25). Tighten nut (22) to
23-27 lb-in. (2.6-3.0 N•m). Slide rubber boot (21) over terminal (25).
12-28 Change 1
TM 9-2320-280-20-3
1 2 - 2 2 . 100 AMPERE REGULATOR (12342944, N3106) REPLACEMENT (Co n t ' d )

7. Install washer (15), lead 2A (16), and nut (17) on yellow (AC) terminal (14). Tighten nut (17) to
18-22 lb-in. (2.0-2.5 N•m). Slide rubber boot (18) over terminal (14).
8. Connect regulator plug (1) to voltage regulator (4).
FOLLOW-ON TASKS: • Lower and secure hood (TM 9-2320-280-10).

Change 1 12-28.1
TM 9-2320-280-20-3
1 2 - 2 2 . 1 . 100 AMPERE ALT E R N ATOR CABLE (12446821-2) REPLACEMENT
This task covers:

INITIAL SETUP:
M1026A1, M1097, M1097A1, M1097A2, M1123 TM 9-2320-280-24P
General mechanic’s tool kit: • Battery ground cables disconnected (para. 4-73).
automotive (Appendix B, Item 1) • Hood raised and secured (TM 9-2320-280-10).
• Engine access cover removed (para. 10-15).
Materials/Parts
Two lockwashers (Appendix G, Item 114.1)
a. Removal
1. Slide back rubber boot (1) and remove nut (3), lockwasher (4), washer (5), fuse (2), insulator (6),
cable (7), and bushing (8) from positive stud (9). Discard lockwasher (4).
2. Remove capscrew (11), clamp (12), and cable (7) from bracket (10).
3. Remove nut (17), lockwasher (16), washer (15), and cable (7) from buss bar (14). Discard
lockwasher (16).
4. Remove cable (7) through grommet (18) and from battery box (13).
b. Installation
NOT E
1. Route cable (7) through grommet (18) on battery box (13), and install cable (7) on buss bar (14) with
washer (15), lockwasher (16), and nut (17).
2. Route cable (7) in approximate mounting location over heat shield, and secure cable (7) and
clamp (12) on bracket (10) with capscrew (11).
3. Apply sealant to positive stud (9) and cable (7) so all exposed metallic surfaces are coated.
4. Install bushing (8), cable (7), fuse (2), and insulator (6) on positive stud (9) with washer (5),
lockwasher (4), and nut (3). Tighten nut (3) to 10-15 lb-ft (14-20 N•m). Slide rubber boot (1)
over nut (3).
12-28.2 Change 1
TM 9-2320-280-20-3
1 2 - 2 2 . 1 . 100 AMPERE ALT E R N ATOR CABLE (12446821-2) REPLACEMENT (Cont’d)

• Start engine and check operation of voltmeter gauge (TM 9-2320-280-10).
Change 1 12-29
TM 9-2320-280-20-3
12-23. 100 AMPERE ALTERNATOR (12340912) REPLACEMENT

This task covers:
INITIAL SETUP
Silicone (Appendix C, Item 48) Ž Battery ground cable disconnected (para. 4-73).
Three lockwashers (Appendix G, Item 115) Ž Hood raised and secured (TM 9-2320-280-10).
One mechanic Alternator must be supported during removal
One assistant and installation.
a. Removal
1. Loosen two clamp nuts (12) and remove clamp pins (7) from regulator slots (6).
2. Loosen connector plug (4) and remove regulator (5) from alternator (13) and position
regulator (5) out of the way.
3. Loosen capscrew (20) on alternator adjusting bracket (19), and two capscrews (10) on alternator
mounting bracket (18) and support bracket (17).
4. Remove two drivebelts (1) from alternator pulley (2).
WARNING
Alternator must be supported during removal and installation. Failure
to do this may cause injury to personnel or damage to equipment.
5. Remove capscrew (14), lockwasher (15), and washer (16) from alternator (13) and adjusting
NOTE
Ž Perform step 7 for vehicles with new alternator support bracket
configuration.
Ž In some cases, a thru-bolt and nut may be present on mounting
bracket instead of standard capscrews and washers.
6. Remove two capscrews (10), lockwashers (11), and alternator (13) from mounting bracket (18) and
support bracket (17). Discard lockwashers (11).
7. Remove two capscrews (10), lockwashers (11), washer (22), spacer (24), and alternator (13) from power
steering lines bracket (23), support bracket (17), and mounting bracket (18). Discard lockwashers (11).
8. Remove guard (9) and two clamp straps (8) from alternator (13).
9. Remove alternator pulley (2) (para. 4-3).
b. Installation
1. Install alternator pulley (2) (para. 4-3).

2. Install two clamp straps (8) and guard (9) on alternator (13).
NOTE
Ž Perform step 4 for vehicles with new alternator support bracket
configuration.
Ž In some cases, a thru-bolt and nut may be present on mounting
3. Install alternator (13) on mounting bracket (18) and support bracket (17) with two lockwashers (11)
and capscrews (10). Tighten capscrews (10) finger tight.
12-30
TM 9-2320-280-20-3
12-23. 100 AMPERE ALTERNATOR (12340912) REPLACEMENT (Cont’d)

4. Position alternator (13) on mounting bracket (18) (with support bracket (17) and power steering
lines bracket (23) on the outside of alternator mounting flange (21)) and install spacer (24),
washer (22), two lockwashers (11), and capscrews (10).
5. Align alternator (13) with hole in adjusting bracket (19), and install washer (16), lockwasher (15),
and capscrew (14). Tighten capscrew (14) finger tight.
6. Install two drivebelts (1) on alternator pulley (2).
7. Fill alternator receptacle (3) with silicone.
8. Install regulator (5) on alternator (13) and secure connector plug (4) between alternator (13) and
regulator (5).
9. Ensure guard (9) is positioned in rear clamp (8). Install clamp pins (7) into regulator slots (6).
Tighten two clamp nuts (12) to 40 lb-in. (4.5 NŽm).
FOLLOW-ON TASKS: Ž Adjust drivebelts (para. 3-82).

Ž Connect battery ground cable (para. 4-73).
12-31
TM 9-2320-280-20-3
1 2 - 2 4 . 100 AMPERE ALT E R N ATOR (12342944) REPLACEMENT

This task covers:
INITIAL SETUP:
M1026A1, M1097, M1097A1, M1097A2, M1123 One assistant
Breaker bar, 3/8 in. (Appendix B, Item 2)
Equipment Condition
Materials/Parts • Battery ground cable removed (para. 4-73).
Lockwasher (Appendix G, Item 108) • Hood raised and secured (TM 9-2320-280-10).
Lockwasher (Appendix G, Item 136) • Voltage regulator removed (para. 12-22).
Two lockwashers (Appendix G, Item 138) General Safety Instructions
Alternator must be supported during removal and
installation.
a. Removal
NOT E
1. Slide back rubber boot (4) and remove capscrew (1), lockwasher (2), washer (3), and ground cable (5)
from alternator (6). Discard lockwasher (2).
2. Slide back rubber boot (18) and remove nut (21), lockwasher (20), washer (19), alternator positive
cable (17), nut (16.2), and washer (16.1) from positive stud (16). Discard lockwasher (20).
NOT E
• Perform steps 3 and 4 for 6.2 L engine only.
• Perform step 5 for 6.5 L engine only.
• In some cases, a thru-bolt and nut may be present on mounting
3. Loosen capscrews (11) and (13) on alternator adjusting bracket (8) and two capscrews (23) from
alternator (6), alternator mounting bracket (25), and support bracket (24).
NOT E
All “A2” models except the M997A2 are equipped with serpentine belts.
4. Remove two drivebelts (7) from alternator pulley (14).
5. Position 3/8-inch breaker bar on belt tensioner (22), move tensioner (22) clockwise, and remove
drivebelt (7) from alternator pulley (14).
WARNING
Alternator must be supported during removal and installation. Failure to
support alternator may cause injury to personnel or damage to equipment.
6. Remove capscrew (11), lockwasher (10), and washer (9) from alternator (6) and adjusting bracket (8).
12-32 Change 1
TM 9-2320-280-20-3
1 2 - 2 4 . 100 AMPERE ALT E R N ATOR (12342944) REPLACEMENT (Co n t ' d )
Change 1 12-33
TM 9-2320-280-20-3

7. Remove capscrew (13), washer (12), and alternator adjusting bracket (8) from alternator mounting
bracket (25).
8. Remove two capscrews (4), lockwashers (5), washers (6), and spacer (10) from alternator (12), power
steering lines bracket (7), support bracket (8), and alternator mounting bracket (11). Discard
lockwashers (5).
9. Remove alternator (12).
10. Remove three capscrews (1), washers (2), bushings (13), and fan guard assembly (3) from alternator (12).
11. Remove alternator pulley (25) (para. 4-3).
b. Installation
1. Install alternator pulley (25) (para. 4-3).

2. Install fan guard assembly (3) on alternator (12) with three bushings (13), washers (2), and capscrews (1).
NOT E
In some cases, a thru-bolt and nut may be present on mounting
3. Position alternator (12) on alternator mounting bracket (11) (with support bracket (8) and power
steering lines bracket (7) on the outside of alternator mounting flange (9) and install spacer (10), two
washers (6), lockwashers (5), and capscrews (4).
4. Install alternator adjusting bracket (19) on alternator mounting bracket (11) with washer (20),
lockwasher (21), and capscrew (22).
NOT E
Perform step 4.1 for 6.2L only.
4.1. Tighten capscrew (22) to 40 lb-ft (54 N•m).
NOT E
Perform step 5 for 6.2L only.
5. Align alternator (12) with adjusting bracket (19) and install washer (23), and capscrew (24). Do not
tighten capscrew (24) on 6.2 L only. On 6.5 L tighten capscrew (24) to 40 lb-ft (54 N•m).
NOT E
6. Install washer (26.1), nut (26.2), and positive cable (27) on positive stud (26) with washer (29),
lockwasher (30), and nut (31). Tighten nut (31) to 10-15 lb-ft (14-20 N•m).
7. Install ground cable (17) on alternator (12) with washer (15), lockwasher (14), and capscrew (32).
Tighten capscrew (32) to 8-12 lb-ft (11-16 N•m).
NOT E
• Perform step 8 for 6.2L only.
• Perform step 9 for 6.5L only.
8. Install two drivebelts (18) on alternator pulley (25).
9. Position 3/8-in. breaker bar on belt tensioner (33), move tensioner (33) clockwise and install belt (18)
on alternator pulley (25).
10. Install rubber boots (16) and (28) over cables (17) and (27).
12-34 Change 1
TM 9-2320-280-20-3
FOLLOW-ON TASKS: • Install voltage regulator (para. 12-22).

• Adjust alternator belts (para. 3-81) (All except “A2” vehicles).
• Battery ground cable installed (para. 4-73).
Change 1 12-34.1
TM 9-2320-280-20-3
1 2 - 2 4 . 1 . 100/200 AMPERE DUAL VOLTAGE ALT E R N ATOR AND REGULAT O R

CONVERSION
This task covers:
a. Part Fabrication c. 200 Ampere Dual Voltage Alternator and Regulator
b. 100 Ampere Dual Voltage Alternator and Installation
and Regulator Installation
INITIAL SETUP:
Grease (Appendix C, Item 25) • Battery ground cable disconnected (para. 4-73).
Sealant (Appendix C, Item 38) • Hood raised and secured (TM 9-2320-280-10).
Alternator (NSN 2920-01-907-0532) • Regulator removed (para. 12-22).
Lockwasher (Appendix G, Item 108) • Alternator removed (para. 12-23).
NOT E
This task is for single voltage vehicle systems (basic and “A1” models) only.
a. Part Fabrication
Refer to appendix D, figure D-121.
b. 100 Ampere Dual Voltage Alternator and Regulator Installation
1. Remove nut (1), washer (2), and pulley (3) from shaft (6) on alternator assembly (5).
2. Remove nut (1) and washer (2) from shaft (6) of replacement 100 ampere alternator assembly (5).
3. Install previously removed pulley (3) on woodruff key (4) and shaft (6) with washer (2) and nut (1).
4. Place alternator assembly (5) in a soft-jawed vise and tighten nut (1) to 120 lb-ft (163 N•m). Remove
alternator assembly (5) from vise.
12-34.2 Change 1
TM 9-2320-280-20-3

CONVERSION (Co n t ’ d )
Change 1 12-34.3
TM 9-2320-280-20-3
1 2 - 2 4 . 1 100/200 AMPERE DUAL VOLTAGE ALT E R N ATOR AND REGULAT O R

NOT E
Do not connect electrical connections when performing step 5.
5. Install alternator assembly (para. 12-23).
6. Remove screw (3), lockwasher (2), and washer (1) from regulator (16). Discard lockwasher (2).
7. Install ground wire (6), washer (1), lockwasher (2), and screw (3) on regulator (16). Tighten screw (3)
to 88-94 lb-in. (10-11 N•m).
8. Route ground wire (6) around regulator (16) to 14-volt stud (7), remove nut (8) from stud (7), and
install ground wire (6) on stud (7) with nut (8). Tighten nut (8) to 45-55 lb-ft (5-6 N•m).
9. Apply sealant to nut (8) and stud (7).
10. Remove screw (24), lockwasher (23), and washer (22) from ground point (25) on alternator
assembly (17). Discard lockwasher (23).
11. Install lead 3B (5), washer (22), lockwasher (23), and screw (24) to ground point (25) on alternator
assembly (17). Tighten screw (24) to 75-85 lb-in. (8-10 N•m).
12. Remove nut (21) and washer (20) from positive terminal (18) on alternator assembly (17).
13. Install red boot (19) on lead 5A (4).
14. Install lead 5A (4) on positive terminal (18) on alternator assembly (17) with washer (20) and
nut (21). Tighten nut (21) to 65-70 lb-in. (7-8 N•m).
15. Apply grease to positive terminal (18) and lead 5A (4), and slide boot (19) over positive terminal (18).
16. Remove nut (13) from IGN terminal (9).
17. Install black boot (12) on lead 568A (11).
18. Install lead 568A (11) and nut (13) on IGN terminal (9). Tighten nut (13) to 23-27 lb-in. (2-3 N•m).
19. Apply grease to IGN terminal (9), lead 568A (11), and inside of boot (12), and slide boot (12) over
IGN terminal (9).
20. Remove nut (14) from AC terminal (15).
21. Install black boot (12) on lead 2A (10).
22. Install lead 2A (10) and nut (14) on AC terminal (15). Tighten nut (14) to 18-22 lb-in. (2-3 N•m).
23. Apply grease to AC terminal (15), lead 2A (10), and inside of black boot (12), and slide boot (12) over
AC terminal (15).
12-34.4 Change 1
TM 9-2320-280-20-3

Change 1 12-34.5
TM 9-2320-280-20-3

c. 200 Ampere Dual Voltage Alternator and Regulator Installation
1. Remove nut (1) and washer (2) from shaft (6) of alternator assembly (5).
2. Install previously removed pulley (3) on woodruff key (4) and shaft (6) with washer (2) and nut (1).
3. Place alternator assembly (5) in a soft-jawed vise, and tighten nut (1) to 115-125 lb-ft (156-170 N•m).
12-34.6 Change 1
TM 9-2320-280-20-3

NOT E
Do not connect electrical connections when performing step 4.
4. Install alternator assembly (para. 12-23).
5. Remove screw (13), lockwasher (14), and washer (15) from regulator (19). Discard lockwasher (14).
6. Install ground wire (16), washer (15), lockwasher (14), and screw (13) on regulator (19). Tighten
screw (13) to 88-94 lb-in. (10-11 N•m).
7. Route ground wire (16) around regulator (19) to 14-volt stud (18), remove nut (17) from stud (18),
and install ground wire (16) on stud (18) with nut (17). Tighten nut (17) to 45-55 lb-in. (5-6 N•m).
8. Apply sealant to nut (17) and stud (18).
9. Assemble dummy plug (7) by installing plug (8) in shell (9).
10. Remove lead 568 (20) from lead 568A (11). Discard lead 568 (20).
11. Install dummy plug assembly (7) in lead 568A (11).
12. Secure lead 568A (11) to electrical harness (12) with tiedown strap (10).
Change 1 12-34.7
TM 9-2320-280-20-3

13. Remove nut (12), lockwasher (11), and washer (10) from ground stud (7) on alternator assembly (6).
14. Install ground strap (8), lead 3B (9), washer (10), lockwasher (11), and nut (12) on alternator
assembly (6).
15. Remove nut (2) and washer (3) from positive terminal (5).
16. Install lead 6 (4), washer (3), and nut (2) to positive terminal (5) on alternator assembly (6).
17. Apply grease to positive terminal (5), lead 6 (4), and inside of boot (1), and slide boot (1) over positive
terminal (5).
12-34.8 Change 1
TM 9-2320-280-20-3

18. Remove nut (15) from IGN terminal (14) on regulator (13).
19. Install boot (17) on lead 5A (16).
20. Install lead 5A (16) to IGN terminal (14) on regulator (13) with nut (15). Tighten nut (15) to
23-27 lb-in. (2-3 N•m).
21. Apply grease to IGN terminal (14), lead 5A (16), and inside of boot (17), and slide boot (17) over IGN
terminal (2).
22. Remove nut (18) from AC terminal (21) on regulator (13).
23. Install boot (20) on lead 2A (19).
24. Install lead 2A (19) to AC terminal (21) on regulator (13) with nut (18). Tighten nut (18) to
18-22 lb-in. (2-3 N•m).
25. Apply grease to AC terminal (21), lead 2A (19), and inside of boot (20), and slide boot (20) over AC
terminal (21).
FOLLOW-ON TASKS: • Connect battery ground cable (para. 4-73).

Change 1 12-35
TM 9-2320-280-20-3
Section IV. ARCTIC WINTERIZATION KITS MAINTENANCE
1 2 - 2 5 . ARCTIC WINTERIZATION KITS MAINTENANCE TASK SUMMARY
TA S K PA G E
PROCEDURES
PA R A . NO.
12-26. Arctic Heater Fuel Pump Replacement 12-38

12-27. Arctic Heater Fuel Filter Assembly Replacement 12-40
12-28. Arctic Heater Fuel Supply Tube Assembly Replacement 12-42
12-29. Arctic Heater Tank-to-Hose Fuel Supply Line Replacement 12-43
12-30. Arctic Heater Fuel Supply Hose Replacement 12-44
12-31. Arctic Heater Pump-to-Hose Fuel Supply Line Replacement 12-45
12-32. Arctic Heater Pump-to-Bulkhead Fuel Supply Line Replacement 12-46
12-33. Arctic Heater Fuel Supply Line Bulkhead Coupling Replacement 12-48
12-34. Arctic Heater Filter-to-Bulkhead Fuel Supply Line Replacement 12-50
12-35. Arctic Heater Filter-to-Heater Fuel Supply Hose Replacement 12-52
12-36. Arctic Heater CDR Valve Tube Assembly Replacement 12-53
12-37. Arctic Heater Plenum Assembly Replacement 12-55
12-38. Arctic Heater Plenum Hose Replacement 12-56
12-39. Arctic Heater Plenum Cover Replacement 12-57
12-40. Arctic Heater Regulator Replacement 12-58
12-41. Arctic Heater Assembly Replacement 12-59
12-42. Arctic Heater Control Box Assembly Replacement 12-61
12-42.1. Arctic Heater Control Cable Maintenance 12-62.2
12-43. Arctic Heater Control Box Assembly Maintenance 12-64
12-44. Arctic Heater Bracket Assembly Replacement 12-66
12-45. Arctic Heater Battery Box Plugs Replacement 12-67
12-46. Arctic Heater Front Cowl Insulation Replacement 12-68
12-47. Arctic Heater Diverter Box Cover Replacement 12-69
12-48. Arctic Heater Exhaust Diverter Cable Assembly Maintenance 12-70
12-48.1. Arctic Heater Ducting Replacement 12-70.2
12-48.2. Arctic Heater Oil Pan Shroud Replacement 12-70.4
12-49. Arctic Diverter Box Maintenance 12-72
12-50. Arctic Defroster Ducting Replacement 12-73
12-51. Arctic Left Defroster Nozzle Replacement 12-75
12-52. Arctic Right Defroster Nozzle Replacement 12-78
12-53. Arctic Heater Nozzle Replacement 12-79
12-54. Arctic Heater Hose Replacement 12-80
12-55 Arctic Diverter Box Cover Replacement 12-81
12-56. Arctic Diverter Ducting Replacement 12-82
12-36 Change 1
TM 9-2320-280-20-3
Section IV. ARCTIC WINTERIZATION KITS MAINTENANCE
12-25. ARCTIC WINTERIZATION KITS MAINTENANCE TASK SUMMARY (Cont’d)
TASK PAGE
PARA. PROCEDURES
NO.
12-57. Swingfire Heater Water Jacket Replacement 12-83

12-58. Swingfire Heater U-Clamps Replacement 12-85
12-59. Swingfire Heater Brushguard and Shield Assembly Replacement 12-86
12-60. Swingfire Heater Exhaust Pipe Assembly Replacement 12-87
12-61. Swingfire Heater Windshield Washer Reservoir 12-88
Plate Replacement
12-62. Swingfire Heater Hood Guard Replacement 12-89
12-63. Swingfire Heater Radiator Lower Tube Assembly Replacement 12-90
12-64. Swingfire Heater Inlet Hose and Tee Replacement 12-92
12-65. Swingfire Heater Pump Assembly, Bracket, and 12-93
Lower Hose Replacement
12-66. Swingfire Heater Water Jacket to Pump and 12-95
Tee Hoses Replacement
12-67. Swingfire Relay and Harness Assembly Replacement 12-97
12-68. Swingfire Heater Harness Assembly Replacement 12-99
12-69. Swingfire Circuit Breaker and Harness Lead Replacement 12-102
12-70. Swingfire Windshield Washer Pump Harness 12-103
Extension Replacement
12-37
TM 9-2320-280-20-3
1 2 - 2 6 . ARCTIC HEATER FUEL PUMP REPLACEMENT
This task covers:

INITIAL SETUP:
M966, M966A1, M996, M996A1, M997, TM 9-2320-280-10
M997A1, M997A2, M998, M998A1, M1025, TM 9-2320-280-24P
M1025A1, M1025A2, M1037, M1038, M1038A1,
M1121 Equipment Condition
Tools
automotive (Appendix B, Item 1) Do not perform this procedure near fire, flames,
or sparks.
Materials/Parts
WARNING

a. Removal
CAUTION
Cover or plug all open hoses and connections immediately after

NOT E
• Have drainage container ready to catch fuel.
• Prior to removal, tag leads for installation.
• Fuel pump is located under right rear passenger seat floor
along frame.
1. Disconnect lead 402A (13) from wiring harness lead (14).
2. Disconnect pump-to-tank fuel supply line (11) from connector (12).
3. Remove connector (12) from fuel pump inlet (11.1).
NOT E
Proceed to step 5 for M996, M996A1, M997, M997A1, M997A2,
M998, M998A1, M1038, and M1038A1 models only. Perform step 4
for all other models.
4. Remove cap (7) and connector (6) from fuel pump tee (5).
5. Remove fuel supply line (8) and connector (6) from fuel pump tee (5).
6. Disconnect tube assembly (10) from connector (9).
7. Remove connector (9) from fuel pump tee (5).
8. Remove two locknuts (17), washers (2), ground lead 416A (16), lockwasher (15), clamp (18), two
capscrews (3), washers (2), and fuel pump (4) from mounting bracket (1). Discard locknuts (17) and
lockwasher (15).
9. Remove fuel pump tee (5) from fuel pump outlet (4.1).
10. Inspect connectors (6), (9), and (12) for damaged threads or cracks. Replace if cracked or damaged.
12-38 Change 1
TM 9-2320-280-20-3
1 2 - 2 6 . ARCTIC HEATER FUEL PUMP REPLACEMENT( C o n t ’ d )
b. Installation
1. Install fuel pump (4) and ground lead 416A (16) on mounting bracket (1) with washer (2), capscrew (3),
lockwasher (15), washer (2), and locknut (17). Tighten locknut (17) to 8 lb-ft (11 N•m).
2. Install fuel pump (4) on mounting bracket (1) with washer (2), capscrew (3), clamp (18), washer (2),
and locknut (17). Tighten locknut (17) to 8 lb-ft (11 N•m).
3. Apply sealing compound to threads of fuel pump inlet (11.1) and install connector (12) on fuel pump
inlet (11.1).
4. Apply sealing compound to threads of connector (12) and connect pump-to-tank fuel supply line (11)
to connector (12).
5. Connect lead 402A (13) to wiring harness lead (14).
6. Apply sealing compound to threads of fuel pump outlet (4.1) and install fuel pump tee (5) on fuel
pump outlet (4.1).
7. Apply sealing compound to threads of fuel pump tee (5) and install connector (9) on fuel pump tee (5).
8. Apply sealing compound to threads of connector (9) and install tube assembly (10) on connector (9).
NOT E
Proceed to step 11 for M996, M996A1, M997, M997A1, M997A2,
M998, M998A1, M1038, and M1038A1 models. Perform steps
9 and 10 for all other models.
9. Apply sealing compound to threads of connector (6) and install connector (6) on fuel pump tee (5).
10. Install cap (7) on connector (6).
11. Apply sealing compound to threads of connector (6) and install connector (6) on fuel pump tee (5)
and fuel supply line (8).
FOR M996, M996A1, M997,

M997A1, M997A2, M998,
M998A1, M1038, AND
M1038A1 MODELS
FOLLOW-ON TASKS: • Connect battery ground cable (para. 4-73).

• Operate arctic heater (TM 9-2320-280-10) and check for fuel leaks.
Change 1 12-39
TM 9-2320-280-20-3
12-27. ARCTIC HEATER FUEL FILTER ASSEMBLY REPLACEMENT

This task covers
lNITIAL SETUP:
Sealing compound (Appendix C, Item 44) Do not perform this procedure near fire, flames,
or sparks.
WARNING

a. Removal
CAUTION
NOTE
Have drainage container ready to catch fuel.
1. Disconnect fuel supply line (12) from elbow (9).
2. Loosen clamp (2) and disconnect filter-to-heater fuel supply hose (1) from connector (7).
3. Remove two nuts (11), capscrews (3), washers (4), shield (10), filter assembly (8), and spacer (5) from
body (6).
4. Remove elbow (9) and connector (7) from filter assembly (8).
5. Inspect elbow (9) and connector (7) for damaged threads or cracks. Replace if cracked or damaged.
b. Installation
1. Apply sealing compound to threaded ends of elbow (9) and connector (7) and install elbow (9) and
connector (7) on filter assembly (8).
2. Install spacer (5), filter assembly (8), and shield (10) on body (6) with two washers (4), capscrews (3),
and nuts (11). Tighten nuts (11) to 16-30 lb-in. (2-3 NŽm).
3. Connect filter-to-heater fuel supply hose (1) to connector (7) with clamp (2).
4. Connect fuel supply line (12) to elbow (9).
12-40
TM 9-2320-280-20-3
12-27. ARCTIC HEATER FUEL FILTER ASSEMBLY REPLACEMENT (Cont’d)
FOLLOW-ON TASK: Operate arctic heater (TM 9-2320-280-10) and check for fuel leaks.
12-41
TM 9-2320-280-20-3
12-28. ARCTIC HEATER FUEL SUPPLY TUBE ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
Sealing compound (Appendix C, Item 44) Fuel tank removed (para. 3-24).
a. Removal
1. Mark position of fuel supply tube assembly (2) on access cover (3).
2. Disconnect arctic fuel supply line (4) from fuel supply tube assembly (2).
3. Remove tube assembly (2) from fuel tank (1).
b. Installation
1. Apply sealing compound to threads of fuel supply tube assembly (2) and install fuel supply tube
assembly (2) on fuel tank (1).
2. Apply sealing compound to fuel supply line (4) and connect fuel supply line (4) to fuel supply tube
assembly (2).
FOLLOW-ON TASKS: Ž Install fuel tank (para. 3-24).

Ž Operate arctic heater (TM 9-2320-280-10) and check for fuel leaks.
12-42
TM 9-2320-280-20-3
12-29. ARCTIC HEATER TANK-TO-HOSE FUEL SUPPLY LINE REPLACEMENT

This task covers:
INITIAL SETUP:
General mechanic’s tool kit: Fuel tank removed (para. 3-24).
Materials/Parts Do not perform this procedure near fire, flames,
Sealing compound (Appendix C, Item 44) or sparks.
Manual References
TM 9-2320-280-10
TM 9-2320-280-24P
WARNING
a. Removal
CAUTION
NOTE
1. Disconnect tank-to-hose fuel supply line (3) from fuel supply tube assembly (2).
2. Remove capscrew (4), clamp (5), and tank-to-hose fuel supply line (3) from fuel tank (1).
b. Installation
1. Apply sealing compound to threads of tank-to-hose fuel supply line (3) and connect fuel supply line (3)
to fuel supply tube assembly (2).
2. Install tank-to-hose fuel supply line (3) on fuel tank (1) with clamp (5) and capscrew (4).

Ž Operate arctic heater (TM 9-2320-280-10) and check for fuel leaks.
12-43
TM 9-2320-280-20-3
12-30. ARCTIC HEATER FUEL SUPPLY HOSE REPLACEMENT

This task covers:
lNITIAL SETUP:
General mechanic’s tool kit: Do not perform this procedure near fire, flames,
automotive (Appendix B, Item 1) or sparks.
Manual References
TM 9-2320-280-10
TM 9-2320-280-24P
WARNING
a. Removal
CAUTION
NOTE
Loosen two clamps (4) and remove fuel supply hose (3) from tank-to-hose fuel supply line (2) and pump-
to-hose fuel supply line (1).
b. Installation
1. Connect hose (3) to tank-to-hose fuel supply line (2) with clamp (4).
2. Connect hose (3) to pump-to-hose fuel supply line (1) with clamp (4).
FOLLOW-ON TASKS: Operate arctic heater (TM 9-2320-280-10) and check for fuel leaks.
12-44
TM 9-2320-280-20-3
12-31. ARCTIC HEATER PUMP-TO-HOSE FUEL SUPPLY LINE REPLACEMENT

This task covers:
INITIAL SETUP:
or sparks.
WARNING

a. Removal
CAUTION
NOTE
1. Loosen clamp (5) and disconnect fuel supply hose (4) from pump-to-hose fuel supply line (3).
2. Remove pump-to-hose fuel supply line (3) from connector (2) on fuel pump (1).
3. Inspect connector (2) for damaged threads or cracks. Replace if cracked or damaged.
b. Installation
1. Apply sealing compound to threads of connector (2) and connect pump-to-hose fuel supply line (3) to
connector (2) on fuel pump (1).
2. Connect fuel supply hose (4) to pump-to-hose fuel supply line (3) with clamp (5).
12-45
TM 9-2320-280-20-3
12-32. ARCTIC HEATER PUMP-TO-BULKHEAD FUEL SUPPLY LINE REPLACEMENT

This task covers:
INITIAL SETUP:
or sparks.
WARNING
a. Removal
CAUTION

NOTE
1. Disconnect pump-to-bulkhead fuel supply line (2) from connector (1).
2. Remove pump-to-bulkhead fuel supply line (2) from bulkhead coupling elbow (3).
NOTE
Perform steps 3 and 4 for M996, M996A1, M997, M997A1,
M997A2, M998, M998A1, M1038, and M1038A1 models only.
3. Disconnect rear pump-to-bulkhead fuel supply line (5) from connector (4).
4. Remove rear pump-to-bulkhead fuel supply line (5) from rear bulkhead coupling elbow (6).
5. Inspect connectors (1) and (4) and bulkhead coupling elbows (3) and (6) for damaged threads or
cracks. Replace if cracked or damaged.
b. Installation
NOTE
M997A2, M998, M998A1, M1038 and M1038A1 models only.
1. Apply sealing compound to threads of connector (4) and install rear pump-to-bulkhead fuel supply
line (5) on connector (4).
2. Apply sealing compound to threads of rear bulkhead coupling elbow (6) and connect rear pump-to-
bulkhead fuel supply line (5) to rear bulkhead coupling elbow (6).
3. Apply sealing compound to threads of connector (1) and install pump-to-bulkhead fuel supply line (2)
on connector (1).
4. Apply sealing compound to threads of bulkhead Coupling elbow (3) and connect pump-to-bulkhead
fuel supply line (2) to bulkhead coupling elbow (3).
12-46
TM 9-2320-280-20-3
12-32. ARCTIC HEATER PUMP-TO-BULKHEAD FUEL SUPPLY LINE REPLACEMENT (Cont’d)
12-47
TM 9-2320-280-20-3
12-33. ARCTIC HEATER FUEL SUPPLY LINE BULKHEAD COUPLING REPLACEMENT

This task covers:
INITIAL SETUP:
or sparks.
WARNING
a. Removal
CAUTION

NOTE
1. Disconnect pump-to-bulkhead fuel supply line (1) from elbow (2).
2. Disconnect elbow (2) from coupling half (5).
3. Remove coupling nut (3) and washer (4) from bulkhead (8) and coupling half (5).
4. Disconnect filter-to-bulkhead fuel supply line (7) from elbow (6).
5. Remove coupling half (5) from elbow (6).
6. Inspect elbows (2) and (6) and coupling half (5) for damaged threads or cracks. Replace if cracked or
damaged.
b. Installation
1. Apply sealing compound to threads of elbows (2) and (6).

2. Connect elbow (6) to coupling half (5).
3. Connect filter-to-bulkhead fuel supply line (7) to elbow (6).
4. Install coupling half (5) on bulkhead (8) with washer (4) and coupling nut (3).
5. Connect elbow (2) to coupling half (5).
6. Connect pump-to-bulkhead fuel supply line (1) to elbow (2).
12-48
TM 9-2320-280-20-3
12-33. ARCTIC HEATER FUEL SUPPLY LINE BULKHEAD COUPLING REPLACEMENT (Cont’d)
12-49
TM 9-2320-280-20-3
12-34. ARCTIC HEATER FILTER-TO-BULKHEAD FUEL SUPPLY LINE REPLACEMENT

This task covers
INITIAL SETUP:
or sparks.
WARNING
a. Removal
CAUTION
NOTE
1. Disconnect filter-to-bulkhead fuel supply line (2) from bulkhead elbow (8).
2. Disconnect fuel supply line (2) from filter elbow (3).
3. Remove nut (7), washer (5), capscrew (4), washer (5), clamp (6), and fuel supply line (2) from
plenum (1).
4. Inspect filter elbow (3) and bulkhead elbow (8) for damaged threads or cracks. Replace if cracked or
damaged.
b. Installation
1. Apply sealing compound to threads of filter elbow (3) and install fuel supply line (2) on filter
elbow (3).
2. Apply sealing compound to threads of bulkhead elbow (8) and connect fuel supply line (2) to
bulkhead elbow (8).
3. Connect fuel supply line (2) to plenum (1) with clamp (6), washer (5), capscrew (4), washer (5),
and nut (7). Tighten capscrew (4) to 8 lb-ft (11 NŽm).
12-50
TM 9-2320-280-20-3
12-34. ARCTIC HEATER FILTER-TO-BULKHEAD FUEL SUPPLY LINE REPLACEMENT (Cont’d)
12-51
TM 9-2320-280-20-3
12-35. ARCTIC HEATER FILTER-TO-HEATER FUEL SUPPLY HOSE REPLACEMENT

This task covers:
INITIAL SETUP:
General mechanic’s tool kit: Do not perform this procedure near fire, flames,
automotive (Appendix B, Item 1) or sparks.
Manual References
TM 9-2320-280-10
TM 9-2320-280-24P
WARNING
a. Removal
CAUTION
disconnection to prevent contamination. Remove all plugs prior to
connection.
NOTE
1. Remove two clamps (2) and hose (3) from filter connector (4) and heater connector (1).
2. Inspect filter connector (4) and heater connector (1) for damage. Replace if damaged.
b. Installation
1. Install clamps (2) on hose (3).

2. Install hose (3) on heater connector (4) and heater connector (1) with clamps (2).
12-52
TM 9-2320-280-20-3
12-36. ARCTIC HEATER CDR VALVE TUBE ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
General mechanic’s tool kit: Ž Cooling system drained, as required (para. 3-60).
automotive (Appendix B, Item 1) Ž Air horn removed (para. 3-14).
Manual References
TM 9-2320-280-24P
a. Removal
1. Remove clamp (1) and disconnect heater inlet elbow hose (2) from CDR valve tube assembly (19).
2. Remove clamp (4) and disconnect hose (5) from CDR valve (3).
3. Remove clamp (12) and disconnect hose (13) from oil filter tube (11).
4. Remove clamp (9) and disconnect hose (14) from water pump fitting (10). Remove tube
assembly (15).
5. Remove nut (18), two washers (6), clamps (17), and capscrew (7) from heater inlet tube (16) and
tube assembly (19).
6. Remove three clamps (8) and hoses (5), (14), and (13) from tube assembly (15).
12-53
TM 9-2320-280-20-3
12-36. ARCTIC HEATER CDR VALVE TUBE ASSEMBLY REPLACEMENT (Cont’d)
b. Installation
1. Install three clamps (8) on hoses (5), (14), and (13). Install three hoses (5), (14), and (13) on tube
assembly (15) with three clamps (8).
2. Install two clamps (17) on heater inlet tube (16) and tube assembly (19) with two washers (6),
capscrew (7), and nut (18).
3. Install clamp (9) on hose (14), and connect hose (14) to water pump fitting (10) with clamp (9).
4. Install clamp (12) on hose (13), and connect hose (13) to oil filler tube (11) with hose (13) and
clamp (12).
5. Install clamp (4) on hose (5) and connect hose (5) to CDR valve (3) with clamp (4).
6. Install clamp (1) on heater inlet elbow hose (2) and connect heater inlet elbow hose (2) to tube
assembly (19) with clamp (1).
FOLLOW-ON TASKS: Ž Install air horn (para. 3-14).

Ž Fill cooling system (para. 3-60).
12-54
TM 9-2320-280-20-3
12-37. ARCTIC HEATER PLENUM ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
General mechanic’s tool kit: Arctic heater assembly removed (para. 12-41).
Manual References
TM 9-2320-280-24P
a. Removal
1. Remove nut (9), washer (10), capscrew (11), washer (10), and clamp (12) from fuel supply
line (13) and plenum (15).
2. Loosen nut (8) and remove knob (1) and nut (8) from cable assembly core (4).
3. Remove nut (7), washer (6), and cable assembly core (4) from plenum bracket (5).
4. Loosen clamp (3) and remove hose (2) from plenum (15).
5. Remove plenum (15) from receptacle assembly (14).
b. Installation
1. Slide plenum (15) into receptacle assembly (14).

2. Connect hose (2) to plenum (15) with clamp (3).
3. Connect cable assembly core (4) to plenum bracket (5) with washer (6) and nut (7).
4. Install nut (8) and knob (1) on cable assembly core (4).
Install clamp (12) and fuel supply line (13) on plenum (15) with washer (10), capscrew (11),
5.
washer (10), and nut (9).
FOLLOW-ON TASKS: Ž Install arctic heater assembly (para. 12-41).

Ž Adjust exhaust diverter cable (para. 12-48).
12-55
TM 9-2320-280-20-3
12-38. ARCTIC HEATER PLENUM HOSE REPLACEMENT

This task covers:
INITIAL SETUP:
a. Removal
Remove two clamps (2) and plenum hose (1) from adapter (3) and plenum (4).
b. Installation
Connect plenum hose (1) to plenum (4) and adapter (3) with two clamps (2).
12-56
TM 9-2320-280-20-3
1 2 - 3 9 . ARCTIC HEATER PLENUM COVER REPLACEMENT
This task covers:

INITIAL SETUP:
Materials/Parts
Six rivets (Appendix G, Item 177.1)
a. Removal
1. Remove three rivets (1) and retainer (2) from plenum (6).
2. Remove three rivets (5) and retainer (4) from plenum (6).
3. Peel cover (3) back and remove from plenum (6).
4. Clean remaining adhesive from surface of plenum (6).
b. Installation
NOT E
backed cover.
1. Peel backing paper from adhesive-backed cover (3).
NOT E
Ensure cover is attached to all bends and corners.
2. Install cover (3) on plenum (6) by pressing cover (3) firmly in place.
NOT E
Refer to para. 10-66 for rivet installation.
3. Install retainer (4) on plenum (6) with three rivets (5).
4. Install retainer (2) on plenum (6) with three rivets (1).
Change 1 12-57
TM 9-2320-280-20-3
12-40. ARCTIC HEATER REGULATOR REPLACEMENT

This task covers:
INITIAL SETUP:
automotive (NSN 5180-00-177-7033)
Equipment Condition
Materials/Parts Arctic heater diverter box cover removed
Seal (Appendix G, Item 216) (para. 12-47).
a. Removal
1. Loosen clamp (15) and disconnect plenum hose (14) from regulator (1).
2. Remove four locknuts (9), washers (10), capscrews (11), and washers (10) from heater
assembly (13) and cowl panel (12) and pull heater assembly (13) away from cowl panel (12). Discard
locknuts (9).
3. Loosen two clamps (5) and remove two heater pipes (7) from inlet hose (4), outlet hose (3), and two
cowl grommets (6).
4. Disconnect regulator (1) from heat duct (8) and remove regulator (1) from heater assembly (13).
5. Remove seal (2) from regulator (1). Discard seal (2).
b. Installation
1. Install seal (2) on regulator (1).

2. Install regulator (1) on heat duct (8) and heater assembly (13).
3. Route two heater pipes (7) through two cowl grommets (6).
4. Install heater assembly (13) on cowl panel (12) with four capscrews (11), washers (10), locknuts (9),
and washers (10). Tighten locknuts (9) to 17 lb-ft (23 NŽm).
5. Install inlet hose (4) and outlet hose (3) on heater pipes (7) with two clamps (5).
6. Install plenum hose (14) on regulator (1) with clamp (15).
FOLLOW-ON TASKS: Install arctic heater diverter box cover (para. 12-47).
12-58
TM 9-2320-280-20-3
12-41. ARCTIC HEATER ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
General mechanic’s tool kit: Ž Heater boot removed (para. 10-96).
automotive (Appendix B, Item 1) Ž Arctic heater fuel filter removed (para. 12-27).
Ž Arctic heater filter-to-heater fuel supply hose
Materials/Parts removed (para. 12-35).
Thermaseal (Appendix G, Item 238)
Four locknuts (Appendix G, Item 64) General Safety Instructions
Cotter pin (Appendix G, Item 28) Do not perform this procedure near fire, flames,
or sparks.
Manual References
TM 9-2320-280-24P
WARNING

a. Removal
CAUTION

NOTE
1. Disconnect electrical connector (6) from heater assembly (3).
2. Remove setscrew (8) from heater assembly (3) and plenum assembly input port (9).
3. Open two clamps (5) and slide heater assembly (3) from plenum assembly (7) and exhaust pipe (1)
from cowl flange (2). Remove heater assembly (3) and exhaust pipe (1) from mounting bracket
assemblies (4).
4. Remove three capscrews (16) and dust unloader cover plate (15) from air cleaner bracket (17).
5. Remove cotter pin (12) from elbow (11) and exhaust pipe elbow (14). Discard cotter pin (12).
6. Remove four locknuts (13), elbow (11), and thermaseal (10) from cowl (18). Discard thermaseal (10)
and locknuts (13).
12-59
TM 9-2320-280-20-3
12-41. ARCTIC HEATER ASSEMBLY REPLACEMENT (Cont’d)

b. Installation
1. Install heater assembly (4) and exhaust pipe (2) on mounting bracket assemblies (5) with two
clamps (6) finger tight.
2. Align heater assembly outlet port (1) with plenum assembly input port (9) and exhaust pipe (2) with
cowl flange (3). Install heater assembly (4) on plenum assembly input port (9) with setscrew (8).
3. Connect electrical connector (7) to heater assembly (4).
4. Tighten two clamps (6).
5. Install elbow (11) on exhaust pipe elbow (14) with cotter pin (12).
6. Install thermaseal (10) on exhaust pipe (2).
7. Install elbow (11) on cowl (18) with four locknuts (13).
8. Install dust unloader cover plate (15) on air cleaner bracket (17) with three capscrews (16).
FOLLOW-ON TASKS: Ž Install arctic heater fuel filter (para. 12-27).

Ž Install arctic heater filter-to-heater fuel supply hose (para. 12-35).
Ž Install heater boot (para. 10-96).
12-60
TM 9-2320-280-20-3
12-42. ARCTIC HEATER CONTROL BOX ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
General mechanic’s tool kit One mechanic
Materials/Parts Manual References
Nut and lockwasher assembly TM 9-2320-280-24P
(Appendix G, Item 146) Equipment Condition
Lockwasher (Appendix G, Items 115) Battery ground cable disconnected (para. 4-73).
a. Removal
1. Remove nut (6), washer (7), capscrew (11), and washer (7) and disconnect ground lead 416A (9) from
fuel pump bracket (10).
NOTE
Perform step 2 for vehicles not equipped with troop/cargo
winterization kit. Perform step 3 for vehicles equipped with
troop/cargo winterization kit.
2. Disconnect lead 402 (4) from fuel pump lead 402A (5).
3. Disconnect lead 402 (26) from fuel pump jumper lead (25).
4. Remove nut (19), lockwasher (18), and washer (17) and disconnect leads 6B (20), 6C (21), and
400 (22) from power stud (8). Discard lockwasher (18).
5. Remove nut (12) and lockwasher (13), and disconnect leads 416 (15) and 416A (14) from shunt (16).
6. Remove nut and lockwasher assembly (23), capscrew (1), and clamp (2) from heater control box
cable (3) and tunnel (24). Discard nut and lockwasher assembly (23).
12-61
TM 9-2320-280-20-3
12-42. ARCTIC HEATER CONTROL BOX ASSEMBLY REPLACEMENT (Cont’d)
7. Remove grommets (25) and (40) from tunnel (24) and battery box (39), and pull heater control box
cable (3) through tunnel (24) and battery box (39).
8. Remove two screws (37) and clamps (38) from heater control box cable (3) and retainer (41).
9. Disconnect electrical connector (36) from heater (35).
10. Remove screw (34), retaining rod (33), and heater control box cable (3) from tunnel (24).
11. Remove two screws (30), lockwasher (31), heater control box (28), and ground lead 416B (29) from
cowl (32). Discard lockwasher (31).
b. Installation
1. Install heater control box (28) and ground lead 416B (29) on cowl (32) with lockwasher (31) and two
screws (30).
2. Connect electrical connector (36) to heater (35).
3. Install heater control box cable (3) on retainer (41) with two clamps (38) and screws (37).
4. Install heater control box cable (3) on tunnel (24) with retaining rod (33) and screw (34).
5. Push heater control box cable (3) through battery box (39) and tunnel (24), and install grommets (25)
and (40).
6. Install heater control box cable (3) on tunnel (24) with clamp (2), capscrew (1), and nut and
7. Connect leads 416 (15) and 416A (14) to shunt (16) with lockwasher (13) and nut (12).
8. Connect leads 6B (20), 6C (21), and 400 (22) to power stud (8) with washer (17), lockwasher (18), and
nut (19).
NOTE
Perform step 9 for vehicles not equipped with troop/cargo
winterization kit. Perform step 10 for vehicles equipped with
troop/cargo winterization kit.
9. Connect lead 402 (4) to fuel pump lead 402A (5).
10. Connect lead 402 (27) to fuel pump jumper lead (26).
11. Connect ground lead 416A (9) to fuel pump bracket (10) with washer (7), capscrew (11), washer (7),
and nut (6).
12-62
TM 9-2320-280-20-3
1 2 - 4 2 . ARCTIC HEATER CONTROL BOX ASSEMBLY REPLACEMENT( C o n t ’ d )
Change 1 12-62.1
TM 9-2320-280-20-3
1 2 - 4 2 . 1 . ARCTIC HEATER CONTROL CABLE MAINTENANCE
This task covers:

b. Installation
INITIAL SETUP:
General mechanic’s tool kit: • Hood raised and secured (TM 9-2320-280-10).
automotive (Appendix B, Item 1) • Engine right splash shield removed (para. 10-20).
Materials/Parts • Arctic heater assembly removed (para. 12-41).
Cotter pin (Appendix G, Item 27.1)
Manual References
TM 9-2320-280-10
TM 9-2320-280-24P
a. Removal
1. Loosen nut (2) and remove knob (1) and nut (2) from control cable core (6).
2. Remove nut (3), washer (4), and control cable (9) from plenum bracket (5).
3. Remove grommet (8) from cowl opening (7) and push control cable (9) through cowl opening (7).
4. Remove capscrew (15), washer (16), and control cable bracket (17) from diverter box (18).
5. Remove cotter pin (11) and washer (10) from control cable pin (13) and exhaust diverter lever (12).
Discard cotter pin (11).
6. Disconnect cable pin (13) from exhaust diverter lever (12) and remove control cable (9).
b. Installation
1. Install control cable pin (13) on exhaust diverter lever (12) with washer (10) and cotter pin (11).
2. Install control cable bracket (17) on diverter box (18) with washer (16) and capscrew (15).
3. Push control cable (9) through cowl opening (7) and install grommet (8) on cowl opening (7).
4. Connect control cable (9) to plenum bracket (5) with washer (4) and nut (3).
5. Install nut (2) and knob (1) on control cable core (6) and tighten nut (2).
c. Adjustment
1. Loosen screw (14) on control cable pin (13).

2. Ensure knob (1) is pushed all the way in (exhaust position).
3. Ensure exhaust diverter lever (12) on diverter box (18) is in the full vertical position
(exhaust position).
4. Tighten screw (14) on control cable pin (13).
12-62.2 Change 1
TM 9-2320-280-20-3
1 2 - 4 2 . 1 ARCTIC HEATER CONTROL CABLE MAINTENANCE( C o n t ’ d )
FOLLOW-ON TASKS: • Install arctic heater assembly (para. 12-41).

• Install engine right splash shield (para. 10-20).
Change 1 12-63
TM 9-2320-280-20-3
12-43. ARCTIC HEATER CONTROL BOX ASSEMBLY MAINTENANCE

This task covers:
INITIAL SETUP:
General mechanic’s tool kit: Arctic heater control box assembly removed
Manual References
TM 9-2320-280-24P
a. Disassembly
NOTE
Prior to removal, tag all leads for installation.
1. Remove nut (6), washer (4), and toggle switch (5) from control box (9). Disconnect leads (16), (19),
and (22) from toggle switch (5).
2. Remove two screws (21) and circuit breaker (20) from control box (9). Disconnect leads (15), (14),
and (13) from circuit breaker (20).
3. Remove nut (8), washer (7), and toggle switch (10) from control box (9). Disconnect
leads (22), (12) (13), (24), and (23) from toggle switch (10).
4. Remove grommet (18) and harness (17) from control box (9).
5. Remove two screws (2) and LED assembly (1) from control box (9).
6. Remove name plate (3) from control box (9).
b. Assembly
1. Install name plate (3) on control box (9).

2. Install LED assembly (1) on control box (9) with two screws (2).
3. Install grommet (18) and harness (17) on control box (9). Ensure lead (11) and LED assembly (1) are
installed through grommet (18) and out of control box (9).
4. Connect leads (12), (24), (13), (22), and (23) to toggle switch (10). Install toggle switch (10) on control
box (9) with washer (7) and nut (8).
5. Connect leads (15), (14), and (13) to circuit breaker (20). Install circuit breaker (20) on control
box (9) with two screws (21).
6. Connect leads (16), (19), and (22) to toggle switch (5). Install toggle switch (5) on control box (9) with
washer (4) and nut (6).
12-64
TM 9-2320-280-20-3
12-43. ARCTIC HEATER CONTROL BOX ASSEMBLY MAINTENANCE (Cont’d)
FOLLOW-ON TASK: Install arctic heater control box assembly (para. 12-42).
12-65
TM 9-2320-280-20-3
12-44. ARCTIC HEATER BRACKET ASSEMBLY REPLACEMENT
This task covers:

INITIAL SETUP
General mechanic’s tool kit: One mechanic
Two lockwashers (Appendix G, Item 110) Ž Hood raised and secured (TM 9-2320-280-10).
Manual References Ž Arctic heater assembly removed (para. 12-41).
TM 9-2320-280-10
TM 9-2320-280-24P
a. Removal
1. Remove two capscrews (5), lockwashers (4), washers (3), and bracket assembly (2) from cowl (6).
2. Remove clamp (1) from bracket assembly (2).
b. Installation
1. Install clamp (1) on bracket assembly (2).

2. Install bracket assembly (2) on cowl (6) with two washers (3), lockwashers (4), and capscrews (5).
Tighten capscrews (5) to 8 lb-ft (11 NŽm).
FOLLOW-ON TASKS: Ž Install arctic heater (para. 12-41).

Ž Lower and secure hood (TM 9-2320-280-10).
12-66
TM 9-2320-280-20-3
12-45. ARCTIC HEATER BATTERY BOX PLUGS REPLACEMENT

This task covers:
INITIAL SETUP:
General mechanic’s tool kit Battery box cover removed (TM 9-2320-280-10).
Manual References
TM 9-2320-280-10
TM 9-2320-280-24P
a. Removal
Remove three plugs (2) from openings (1) in battery box (3).
b. Installation
Install three plugs (2) on openings (1) in battery box (3).
FOLLOW-ON TASK: Install battery box cover (TM 9-2320-280-10).
12-67
TM 9-2320-280-20-3
12-46. ARCTIC HEATER FRONT COWL INSULATION REPLACEMENT

This task covers:
INITIAL SETUP:
Materials/Parts
NOTE
Right and left front cowl insulation is removed and installed
basically the same. This procedure covers the right front cowl
insulation.
a. Removal
1. Remove four locknuts (11), washers (9), capscrews (8), and retainer (10) from cowl (4). Discard
locknuts (11).
2. Remove four locknuts (7), washers (6), capscrews (5), washers (6), and retainer (3) from cowl (4). Discard
locknuts (7).
3. Starting at base of battery box (1), peel back insulation (2) and work forward.
4. Remove insulation (2) from cowl (4).
5. Clean remaining adhesive from cowl (4).
b. Installation
NOTE
backing.
1. Peel backing paper from adhesive-backed insulation (2).
2. Install insulation (2) on cowl (4) and work toward battery box (l), pressing insulation (2) firmly
in place.
3. Install retainer (10) on cowl (4) with four washers (9), capscrews (8), and locknuts (11).
4. Install retainer (3) on cowl (4) with four washers (6), capscrews (5), washers (6), and
locknuts (7).
12-68
TM 9-2320-280-20-3
1 2 - 4 7 . ARCTIC HEATER DIVERTER BOX COVER REPLACEMENT
This task covers:

INITIAL SETUP:
Materials/Parts
NOT E
a. Removal
1. Remove five rivets (4) and washers (3) from cover (1) and diverter box (2).
2. Peel back cover (1) and remove from diverter box (2).
3. Clean remaining adhesive, dirt, and oil from diverter box (2).
b. Installation
1. Apply adhesive to surface of diverter box (2) and rough surface of cover (1).
2. Install cover (1) on diverter box (2), pressing firmly in place.
3. Secure cover (1) to diverter box (2) with five washers (3) and rivets (4).
4. Ensure cover (1) is attached at all bends and corners of diverter box (2).
5. Remove backing from two data plates (6) and install data plates (6) on cover (1).
6. Remove backing from warning plate (5) and install warning plate (5) on cover (1).
Change 1 12-69
TM 9-2320-280-20-3
12-48. ARCTIC HEATER EXHAUST DIVERTER CABLE ASSEMBLY MAINTENANCE

This task covers
a.Removal c. Adjustment
b. Installation
INITIAL SETUP:
Materials/Parts
Cotter pin (Appendix G, Item 27) Ž Hood raised and secured (TM 9-2320-280-10).
Ž Engine right splash shield removed (para. 10-20).
Ž Arctic heater assembly removed (para. 12-41).
a. Removal
1. Loosen nut (2) and remove knob (1) and nut (2) from cable assembly core (6).
2. Remove nut (3), washer (4), and cable assembly (9) from plenum bracket (5).
3. Remove grommet (8) from cowl opening (7) and pull cable assembly (9) through cowl opening (7).
4. Remove capscrew (15), washer (16), and cable bracket (17) from diverter box (18).
5. Remove cotter pin (11) and washer (10) from cable pin (13) and exhaust diverter lever (12). Disconnect
cable pin (13) from exhaust diverter lever (12) and remove cable assembly (9), Discard cotter pin (11).
b. Installation
1. Install cable pin (13) on exhaust diverter lever (12) with washer (10) and cotter pin (11).
2. Install cable bracket (17) on diverter box (18) with washer (16) and capscrew (15).
3. Push cable assembly (9) through cowl opening (7) and install grommet (8) on cowl opening (7).
4. Connect cable assembly (9) to plenum bracket (5) with washer (4) and nut (3).
5. Install nut (2) and knob (1) on cable assembly core (6) and tighten nut (2) on knob (1).
c. Adjustment
1. Loosen screw (14) on cable assembly core (6) to cable pin (13).
2. Ensure knob (1) is pushed all the way in (exhaust position).
3. Ensure exhaust diverter lever (12) on diverter box (18) is in the full vertical position
(exhaust position).
4. Tighten screw (14) on cable assembly core (6) on cable pin (13).
12-70
TM 9-2320-280-20-3
12-48. ARCTIC HEATER EXHAUST DIVERTER CABLE ASSEMBLY MAINTENANCE(Cont’d)
FOLLOW-ON TASKS: • Install arctic heater assembly (para. 12-41).

• Install engine right splash shield (para. 10-20).
Change 1 12-70.1
TM 9-2320-280-20-3
12-48.1 ARCTIC H E ATER DUCTING REPLACEMENT
This task covers:

INITIAL SETUP:
M997A2, M1025A2, M1043A2, TM 9-2320-280-10
M1045A2, M1097A2, M1123 TM 9-2320-280-24P
General mechanic’s tool kit: • Engine access cover removed (para. 10-15).
automotive (Appendix B, Item 1) • Front radio rack assembly removed, if equipped
(para. 12-132).
Materials/Parts
Two rivets (Appendix G, Item 177.1)
a. Removal
1. Remove two capscrews (4), washers (5), and two radio rack mounting brackets (6) from plenum
panel (7).
2. Remove nine screws (9), retainer (8), and plenum panel (7) from “A” beam (2).
3. Disconnect connector (25) from light switch (12).
4. Remove two locknuts (27), washers (13), capscrews (14), and washers (13) securing instrument
panel (11) to firewall (26). Discard locknuts (27).
5. Remove nut (21), washer (20), capscrew (19), washer (20) from hand throttle bracket (17), steering
column bracket (22), and instrument panel (11).
6. Remove nut (15), screw (18), and hand throttle bracket (17) from instrument panel (11).
7. Remove screw (16) securing panel (11) to firewall (26) and pull panel (11) away from “A” beam (2)
for access to air duct (1).
NOT E
Refer to para. 10-66 for rivet removal.
8. Remove two rivets (10) securing air duct (1) to diverter assembly (3).
9. Remove clamp (24) and air duct (1) from steering column mount (23).
b. Installation
1. Install air duct (1) on steering column mount (23) with clamp (24).
NOTE
2. Install air duct (1) on diverter assembly (3) with two rivets (10).
3. Install panel (11) on firewall (26) with screw (16).
4. Secure panel (11) and hand throttle bracket (17) to steering column bracket (22) with washer (20),
capscrew (19), washer (20), and nut (21).
5. Install hand throttle bracket (17) on instrument panel (11) with screw (18) and nut (15).
6. Secure panel (11) to firewall (26) with two washers (13), capscrews (14), washers (13), and
locknuts (27).
7. Connect connector (25) to light switch (12).
8. Install plenum panel (7) and retainer on “A” beam (2) with nine screws (9).
9. Install two radio rack mounting brackets (6) on plenum panel (7) with two washers (5) and
capscrews (4).
12-70.2 Change 1
TM 9-2320-280-20-3
1 2 - 4 8 . 1 . ARCTIC H E ATER DUCTING REPLACEMENT( C o n t ’ d )
NEW CONFIGURATION

• Install front radio rack assembly, if equipped (para. 12-132).
Change 1 12-70.3
TM 9-2320-280-20-3
1 2 - 4 8 . 2 . ARCTIC HEATER OIL PAN SHROUD REPLACEMENT

This task covers:
INITIAL SETUP:
Applicable Models
_______________ Manual References
________________
M966, M966A1, M997, M997A1, M997A2, TM 9-2320-280-20
M998, M998A1, M1025, M1025A1, M1025A2, TM 9-2320-280-24P
M1037, M1038, M1038A1, M1121 General Safety Instructions
______________________
Tools
____ Do not touch hot exhaust system with bare hands.
Materials/Parts
_____________
Cotter pin (Appendix G, Item 17.1)
Nine locknuts (Appendix G, Item 107.2)
WARNING
Severe injury may result.
a. Removal
1. Remove cotter pin (8) and flex tube (7) from oil pan shroud (6). Discard cotter pin (8).
2. Remove two locknuts (5), washers (4), starter cable bracket (3), and washer (2) from oil pan (1). Discard
locknuts (5).
3. Remove seven locknuts (9), washers (10), and oil pan shroud (6) from oil pan (1). Discard locknuts (9).
b. Installation
1. Install oil pan shroud (6) on oil pan (1) with seven washers (10) and locknuts (9).
2. Install washer (2) and starter cable bracket (3) on oil pan (1) with two washers (4) and locknuts (5).
3. Connect flex tube (7) to oil pan shroud (6) with cotter pin (8).
12-70.4 Change 1
TM 9-2320-280-20-3
1 2 - 4 8 . 2 . ARCTIC HEATER OIL PAN SHROUD REPLACEMENT(Cont'd)
FOLLOW-ON TASK: Install starter (TM 9-2320-280-20).
Change 1 12-71
TM 9-2320-280-20-3
1 2 - 4 9 . ARCTIC D I V E RTER BOX MAINTENANCE
This task covers:

INITIAL SETUP:
M997A2, M1025A2, M1035A2, M1043A2, Pushnut (Appendix G, Item 170)
M1045A2, M1097A2, M1123 Two rivets (Appendix G, Item 196)
Four rivets (Appendix G, Item 200.1)
Tools
automotive (Appendix B, Item 1) Arctic diverter ducting removed (para. 12-56).
a. Removal
1. Remove two screws (14) from transition diverter (12) and transition (13).
2. Remove two screws (8) from diverter (9) and heater (7).
3. Remove screw (5) and clamp (4) from diverter (9)
4. Remove pushnut (11) and disconnect defroster cable core (6) from baffle pin (10). Discard pushnut (11).
5. Pull diverter (9) away from “A” beam (1), loosen two clamps (3), and remove diverter (9) from
defroster flex ducts (2).
b. Disassembly
NOT E
1. Remove four rivets (21) and transition diverter (12) from diverter (9).
2. Remove screw (15), spring (16), and louver (17) from transition diverter (12).
3. Remove two rivets (19), flap (20), and bracket (18) from diverter (9).
c. Assembly
NOT E
1. Install flap (20) and bracket (18) on diverter (9) with two rivets (19).
2. Install louver (17) on transition diverter (12) with spring (16) and screw (15).
3. Install transition diverter (12) on diverter (9) with four rivets (21).
d. Installation
1. Position diverter (9) under “A” beam (1) and connect two defroster flex ducts (2) on diverter (9).
2. Secure flex ducts (2) to diverter (9) with two clamps (3).
3. Connect defroster cable core (6) on baffle pin (10) with pushnut (11).
4. Install transition diverter (12) on transition (13) with two screws (14).
NOT E
upward position before securing control cable to diverter box.
5. Install clamp (4) on diverter (9) with screw (5).
6. Install diverter (9) on heater (7) with two screws (8).
12-72 Change 1
TM 9-2320-280-20-3
1 2 - 4 9 . ARCTIC D I V E RTER BOX MAINTENANCE (Cont’d)
FOLLOW-ON TASK: Install arctic diverter ducting (para. 12-56).
Change 1 12-72.1/(12-72.2 blank)

TM 9-2320-280-20-3
12-50. ARCTIC DEFROSTER DUCTING REPLACEMENT

This task covers:
INITIAL SETUP:
M997A2, M1025A2, M1035A2, TM 9-2320-280-10
M1043A2, M1045A2, M1097A2 TM 9-2320-280-24P
General mechanic’s tool kit Ž Hood raised and secured (TM 9-2320-280-10).
automotive (Appendix B, Item 1) Ž Engine access cover removed (para. 10-15).
Materials/Parts
a. Removal
1. Remove six screws (5), retainer (6), and closeout panel (4) from “A” beam (3).
3. Remove three screws (12) from closeout panel (4) and “A” beam (3).
4. Disconnect left flex duct (2) from left defroster nozzle (1).
5. Remove four screws (18) from panel assembly (17) and “A” beam (3) and pull panel assembly (17)
away from “A” beam (3) for access to right defroster nozzle (13).
6. Disconnect right flex duct (14) from right defroster nozzle (13).
housing (16).
12-73
TM 9-2320-280-20-3
12-50. ARCTIC DEFROSTER DUCTING REPLACEMENT (Cont’d)

b. Installation
1. Connect left flex duct (2) and right flex duct (4) to diverter housing (6) with two clamps (5).
2. Apply adhesive sealant and connect right flex duct (4) to right defroster nozzle (3).
3. Install panel assembly (7) on “A” beam (1) with four screws (8).
4. Apply adhesive sealant and connect left flex duct (2) to left defroster nozzle (9).
5. Install retainer (12) and closeout panel (10) on “A” beam (1) with six screws (11).
7. Install three clamps (15), cable clamp (16), and closeout panel (10) on “A” beam (1) with three
FOLLOW-ON TASKS: Ž Install engine access cover (para. 10-15).

12-74
TM 9-2320-280-20-3
12-51. ARCTIC LEFT DEFROSTER NOZZLE REPLACEMENT

This task covers:
INITIAL SETUP:
M997A2, M1025A2, M1035A2, TM 9-2320-280-10
M1043A2, M1045A2, M1097A2 TM 9-2320-280-24P
General mechanic’s tool kit: Ž Hood raised and secured (TM 9-2320-280-10).
automotive (Appendix B, Item 1) Ž Engine access cover removed (para. 10-15).
Materials/Parts
a. Removal
1. Remove six screws (4) and retainer (5) from closeout panel (3) and “A” beam (6).
clamp (10), closeout panel (3) and “A” beam (6).
3. Remove three screws (12) and closeout panel (3) from “A” beam (6).
4. Disconnect defroster duct (2) from defroster nozzle (1).
12-75
TM 9-2320-280-20-3
12-51. ARCTIC LEFT DEFROSTER NOZZLE REPLACEMENT (Cont’d)
5. Remove locknut (9), lockwasher (10), washer (11), and pin (14) from steering column (15) and
bracket (13), and lower steering column (15). Discard locknut (9) and lockwasher (10).
6. Remove retaining pin (12) from defroster nozzle (2) and bracket (13).
NOTE
7. Turn defroster nozzle (2) counterclockwise and remove from "A" beam (7).
b. Installation
1. Install defroster nozzle (2) on “A” beam (7).

2. Turn defroster nozzle (2) clockwise until defroster nozzle outlets (8) align with windshield frame
louvers (1).
3. Install defroster nozzle (2) on steering column bracket (13) with retaining pin (12).
4. Place steering column (15) in desired position, and install on bracket (13) with pin (14), washer (11),
lockwasher (10), and locknut (9). Tighten locknut (9) to 31 lb-ft (42 NŽm).
5. Apply adhesive sealant and connect defroster duct (3) to defroster nozzle (2).
6. Install retainer (6) and closeout panel (4) on “A” beam (7) with six screws (5).
8. Install closeout panel (4), three clamps (18), and cable clamp (19) on “A” beam (7) with three
12-76
TM 9-2320-280-20-3
12-51. ARCTIC LEFT DEFROSTER NOZZLE REPLACEMENT (Cont’d)

Ž Install engine access cover (para. 10-15).
12-77
TM 9-2320-280-20-3
12-52. ARCTIC RIGHT DEFROSTER NOZZLE REPLACEMENT

This task covers:
INITIAL SETUP:
M997A2, M1025A2, M1035A2, TM 9-2320-280-24P
M1043A2, M1045A2, M1097A2
Equipment Condition
Tools Defroster ducting removed (para. 12-50).
a. Removal
NOTE
Turn defroster nozzle (2) counterclockwise and remove from “A” beam (4).
b. Installation
Install defroster nozzle (2) on “A” beam (4) and turn defroster nozzle (2) clockwise until defroster nozzle
outlets (1) align with windshield frame louvers (3).
FOLLOW-ON TASK: Install defroster ducting (para. 12-50).
12-78
TM 9-2320-280-20-3
12-53. ARTIC HEATER NOZZLE REPLACEMENT
This task covers:

INITIAL SETUP:
M997A2, M1025A2, M1035A2, TM 9-2320-280-24P
M1043A2, M1045A2, M1097A2
Tools

a. Removal
Remove capscrews (3) and (4) and nozzle (2) from left transition (1).
b. Installation
Install nozzle (2) on left transition (1) with capscrews (3) and (4).
12-79
TM 9-2320-280-20-3
12-54. ARCTIC HEATER HOSE REPLACEMENT

This task covers:
INITIAL SETUP:
M997A2, M1025A2, M1035A2, TM 9-2320-280-10
M1043A2, M1045A2, M1097A2 TM 9-2320-280-24P
automotive (Appendix B, Item 1) Ž Engine access cover removed (pars. 10-15).
Materials/Parts
a. Removal
Disconnect heater hose (2) from left transition (1) and right transition (3), and remove heater hose (2).
b. Installation
Apply adhesive sealant and connect heater hose (2) to left transition (1) and right transition (3).
FOLLOW-ON TASKS: Ž Install engine access cover (para. 10-15).

12-80
TM 9-2320-280-20-3
12-55. ARCTIC DIVERTER BOX COVER REPLACEMENT

This task covers:
INITIAL SETUP:
M997A2, M1025A2, M1035A2, TM 9-2320-280-24P
M1043A2, M1045A2, M1097A2
Tools
a. Removal
Remove three capscrews (4) and diverter box cover (3) from right mounting bracket (2) and “A” beam (1).
b. Installation
Install diverter box cover (3) on right mounting bracket (2) and “A” beam (1) with three capscrews (4).
12-81
TM 9-2320-280-20-3
12-56. ARCTIC DIVERTER DUCTING REPLACEMENT

This task covers:
INITIAL SETUP:
M997A2, M1025A2, M1035A2, TM 9-2320-280-24P
M1043A2, M1045A2, M1097A2
Manual Reference
Tools Diverter box cover removed (para. 12-55).

a. Removal
Loosen clamp (1) and remove diverter ducting (2) from diverter transition (3).
b. Installation
Install diverter ducting (2) to diverter transition (3) and tighten clamp (1).
FOLLOW-ON TASK: Install diverter box cover (para. 12-55).
12-82
TM 9-2320-280-20-3
12-57. SWINGFIRE HEATER WATER JACKET REPLACEMENT

This task covers:
INITIAL SETUP:
M966, M966A1, M996, M996A1, M997, TM 9-2320-280-24P
M997A1, M997A2, M998, M998A1, M1025,
M1025A1, M1025A2, M1037, M1038, M1038A1 Equipment Condition
Tools Ž Battery ground cable disconnected (para. 4-73).
Ž Cooling system drained as required (para. 3-60).
a. Removal
1. Remove clamp (2) and inlet hose (1) from water jacket (3).
2. Remove clamp (6) and outlet hose (4) from water jacket (3).
3. Remove nut (10), washer (9), washer (11) and chain retainer (8) from U-clamp assembly (7).
4. Remove three nuts (12), washers (13), two U-bolts (5), and water jacket (3) from two U-clamp
assemblies (7).
12-83
TM 9-2320-280-20-3
12-57. SWINGFIRE HEATER WATER JACKET REPLACEMENT (Cont’d)

b. Installation
1. Install water jacket (3) on two U-clamp assemblies (7) with two U-bolts (5), three washers (13), and
nuts (12).
2. Install chain retainer (8) on U-clamp assembly (7) with washer (11), washer (9), and nut (10).
3. Install outlet hose (4) on water jacket (3) with clamp (6).
4. Install inlet hose (1) on water jacket (3) with clamp (2).
FOLLOW-ON TASKS: Ž Fill cooling system (para. 3-60).

12-84
TM 9-2320-280-20-3
12-58. SWINGFIRE HEATER U-CLAMPS REPLACEMENT

This task covers:
INITIAL SETUP:
M966, M966A1, M996, M996A1, M997, One mechanic
M1025A1, M1025A2, M1037, M1038, M1038A1 Manual References
Tools TM 9-2320-280-24P
Ž Water jacket removed (para. 12-57).
Materials/Parts Ž Wiring harness and relay disconnected
Four lockwashers (Appendix G, Item 115) (para. 12-67).
a. Removal
1. Remove two capscrews (8), lockwashers (7), bracket (5), and U-clamp assembly (6) from cowl (9).
2. Remove two capscrews (1), lockwashers (2), plate (4), and U-clamp assembly (3) from cowl (9).
b. Installation
1. Install U-clamp assembly (3) and plate (4) on cowl (9) with two lockwashers (2) and capscrews (1).
2. Install U-clamp assembly (6) and bracket (5) on cowl (9) with two lockwashers (7) and capscrews (8).
FOLLOW-ON TASKS: Ž Connect wiring harness and relay (para. 12-67).

Ž Install water jacket (para. 12-57).
12-85
TM 9-2320-280-20-3
12-59. SWINGFIRE HEATER BRUSHGUARD AND SHIELD ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
Personnel Required
Applicable Models
One mechanic
M966, M966A1, M996, M996A1, M997, One assistant
M997A1, M997A2, M998, M998A1, M1025,
M1025A1, M1025A2, M1037, M1038, M1038A1 General Safety Instructions
Tools Do not touch hot exhaust system components
General mechanic’s tool kit: with bare hands.
Manual References
TM 9-2320-280-24P
WARNING
a. Removal
Remove eight nuts (3), capscrews (1), washers (2), and brushguard and shield assembly (4) from cowl (5).
b. Installation
Install brushguard and shield assembly (4) on cowl (5) with eight washers (2), capscrews (1), and nuts (3).
12-86
TM 9-2320-280-20-3
12-60. SWINGFIRE HEATER EXHAUST PIPE ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
M966, M966A1, M996, M996A1, M997, Ž Brushguard and shield assembly removed
M997A1, M997A2, M998, M998A1, M1025, (para. 12-59).
M1025A1, M1025A2, M1037, M1038, M1038A1 Ž Battery ground cable disconnected (para. 4-73).
General mechanic’s tool kit: Do not touch hot exhaust system components
automotive (Appendix B, Item 1) with bare hands.
Manual References
TM 9-2320-280-24P
WARNING
a. Removal
1. Remove two screws (6) and harness leads 81B (5) and 81E (4) from thermal switch (7).
2. Remove four nuts (3), washers (2), capscrews (1), and exhaust pipe (8) from cowl (9).
3. Remove thermal switch (7) from exhaust pipe (8).
b. Installation
1. Install thermal switch (7) on exhaust pipe (8).

2. Install exhaust pipe (8) on cowl (9) with four capscrews (1), washers (2), and nuts (3).
3. Connect harness leads 81E (4) and 81B (5) to thermal switch (7) with two screws (6).
FOLLOW-ON TASKS: Ž Install brushguard and shield assembly (para. 12-59).

12-87
TM 9-2320-280-20-3
12-61. SWINGFIRE HEATER WINDSHIELD WASHER RESERVOIR PLATE REPLACEMENT

This task covers:
INITIAL SETUP:
M966, M966A1, M996, M996A1, M997, TM 9-2320-280-24P
M997A1, M997A2, M998, M998A1, M1025,
Tools Ž Protective control box removed (para. 4-5).
Ž Windshield washer reservoir removed
Materials/Parts
NOTE
a. Removal
Remove two rivets (1) and plate (2) from cowl (3).
b. Installation
Install plate (2) on cowl (3) with two rivets (1).
FOLLOW-ON TASKS: ● Install windshield washer reservoir (para. 10-75).

● Install protective control box (para. 45).
12-88
TM 9-2320-280-20-3
12-62. SWINGFIRE HEATER HOOD GUARD REPLACEMENT

This task covers:
INITIAL SETUP:
Materials/Parts
Applicable Models
M966, M966A1, M996, M996A1, M997, Eleven rivets (Appendix G, Item 195)
M1025A1, M1025A2, M1037, M1038, M1038A1
TM 9-2320-280-24P
Tools
NOTE
a. Removal
Remove eleven rivets (1) and guard (2) from hood (3).
b. Installation
Install guard (2) on hood (3) with eleven rivets (1).
12-89
TM 9-2320-280-20-3
12-63. SWINGFIRE HEATER RADIATOR LOWER TUBE ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
M966, M966A1, M996, M996A1, M997, TM 9-2320-280-24P
M997A1, M997A2, M998, M998A1, M1025, Equipment Condition
M1025A1, M1025A2, M1037, M1038, M1038A1
Cooling system drained (para. 3-60).
Tools
Materials/Parts
a. Removal
1. Remove two locknuts (5), washers (3), capscrews (2), and washers (3) from radiator lower tube
assembly (12) and frame bracket (4). Discard locknuts (5).
2. Loosen clamp (9) and disconnect water pump inlet hose (8) from radiator lower tube assembly (12).
3. Loosen clamp (6) and disconnect swingfire heater pump hose (7) from radiator lower tube
assembly (12).
4. Loosen clamp (11) and disconnect surge tank hose (10) from radiator lower tube assembly (12).
5. Loosen clamp (13) and disconnect lower radiator hose (1) from radiator lower tube assembly (12).
6. Remove radiator lower tube assembly (12).
7. Remove clamps (9), (6), (11), and (13) from water pump inlet hose (8), swingfire heater pump hose (7),
surge tank hose (10), and lower radiator hose (1):
b. Installation
1. Install clamps (9), (6), (11), and (13) on water pump inlet hose (8), swingfire heater pump hose (7),
surge tank hose (10), and lower radiator hose (1).
2. Connect lower radiator hose (1) to radiator lower tube assembly (12) with clamp (13).
3. Connect surge tank hose (10) to radiator lower tube assembly (12) with clamp (11).
4. Connect swingfire heater pump hose (7) to radiator lower tube assembly (12) with clamp (6).
5. Connect water pump inlet hose (8) to radiator lower tube assembly (12) with clamp (9).
6. Connect radiator lower tube assembly (12) to bracket (4) with two washers (3), capscrews (2),
12-90
TM 9-2320-280-20-3
12-63. SWINGFIRE HEATER RADIATOR LOWER TUBE ASSEMBLY REPLACEMENT (Cont’d)
FOLLOW-ON TASKS: Fill cooling system (para. 3-60).
12-91
TM 9-2320-280-20-3
12-64. SWINGFIRE HEATER INLET HOSE AND TEE REPLACEMENT

This task covers:
INITIAL SETUP:
M966, M966A1, M996, M996A1, M997, TM 9-2320-280-24P
M1025A1, M1025A2, M1037, M1038, M1038A1
Ž Battery ground cable disconnected (para. 4-73).
Tools Ž Air horn removed (para. 3-14).
General mechanic’s tool kit: Ž Cooling system drained as required (para. 3-60).
a. Removal
1. Loosen clamp (2) and disconnect heater inlet hose (1) from tee (3).
2. Loosen clamps (11) and (4) and remove tee (3) from connector hose (10) and hose (5).
3. Loosen clamp (9) and disconnect connector hose (10) from CDR valve tube (8).
4. Loosen clamp (6) and disconnect hose (5) from water crossover nipple (7).
5. Remove clamps (9), (11), (4), (2), and (6) from connector hose (10), hose (5), and inlet hose (1).
b. Installation
1. Install clamps (9), (11), (4), (2), and (6) on connector hose (10), hose (5), and inlet hose (1).
2. Install connector hose (10) on CDR valve tube (8) with clamp (9).
3. Install hose (5) on water crossover nipple (7) with clamp (6).
4. Install tee (3) on connector hose (10) and hose (5) with clamps (4) and (11).
5. Install heater inlet hose (1) on tee (3) with clamp (2).

Ž Fill cooling system (para. 3-60).
12-92
TM 9-2320-280-20-3
12-65. SWINGFIRE HEATER PUMP ASSEMBLY, BRACKET, AND LOWER HOSE

REPLACEMENT
This task covers:
INITIAL SETUP:
M966, M966A1, M996, MM996A1, M997, TM 9-2320-280-24P
M997A1, M997A2, M998, M998A1, M1025,
Ž Battery ground cable disconnected (para. 4-73).
Tools Ž Cooling system drained as required (para. 3-60).
Materials/Parts
NOTE
a. Removal
1. Disconnect lead 81G (2) and ground wire lead (1) from heater pump leads (3).
2. Loosen clamp (9) and disconnect outlet hose (10) from heater pump (4).
3. Loosen clamps (5) and (7) and disconnect inlet hose (6) from heater pump (4) and radiator lower tube
assembly (8).
4. Remove clamps (5) and (7) from inlet hose (6).
5. Remove clamp (11) and heater pump (4) from bracket (15).
6. Remove two nuts (14), lockwashers (13), and bracket (15) from water pump studs (12). Discard
lockwashers (13).
12-93
TM 9-2320-280-20-3
12-65. SWINGFIRE HEATER PUMP ASSEMBLY, BRACKET, AND LOWER HOSE

b. Installation
1. Install bracket (5) on water pump studs (1) with two lockwashers (2) and nuts (3).
2. Install heater pump (4) on bracket (5) with clamp (6).
3. Install clamps (9) and (11) on inlet hose (10).
4. Install inlet hose (10) on radiator lower tube assembly (12) and heater pump (4) with clamps (9)
and (11).
5. Install clamp (14) on outlet hose (13). Connect outlet hose (13) to heater pump (4) with clamp (14).
6. Connect ground wire lead (15) and lead 81G (7) to heater pump leads (8).

12-94
TM 9-2320-280-20-3
12-66. SWINGFIRE HEATER WATER JACKET TO PUMP AND TEE HOSES REPLACEMENT
This task covers:
INITIAL SETUP:
Manual References
Applicable Models
TM 9-2320-280-24P
M966, M966A1, M996, M996A1, M997,
M1025A1, M1025A2, M1037, M1038, M1038A1 Ž Cooling system drained as required (para. 3-60).
Tools Ž Air horn removed (para. 3-14).
Materials/Parts
Three tiedown straps (Appendix G, Item 239)
a. Removal
1. Remove three tiedown straps (5) from inlet hose (8) and outlet hose (6). Discard tiedown
straps (5).
2. Remove nut (15) and screw (4) from two clamps (16), inlet hose (8), outlet hose (6) and support (2).
3. Remove screw (3) and support (2) from “A” beam (1).
4. Remove clamp (7) and outlet hose (6) from water jacket (10).
5. Remove clamp (9) and inlet hose (8) from water jacket (10).
6. Remove clamp (12) and outlet hose (6) from tee (11).
7. Remove clamp (14) and inlet hose (8) from heater pump (13).
8. Remove clamps (9), (12), (7), (14), and (16) from inlet and outlet hoses (6) and (8).
12-95
TM 9-2320-280-20-3
12-66. SWINGFIRE HEATER WATER JACKET TO PUMP AND TEE HOSES REPLACEMENT
(Cont’d)
b. Installation
1. Install clamps (16), (14), (7), (12), and (9) on inlet and outlet hoses (6) and (8).
2. Install outlet hose (8) on heater pump (13) with clamp (14).
3. Install inlet hose (6) on tee (11) with clamp (12).
4. Connect inlet hose (6) to water jacket (10) with clamp (7).
5. Connect outlet hose (8) to water jacket (10) with clamp (9).
6. Install support (2) on “A” beam (1) with screw (3).
7. Connect inlet and outlet hoses (6) and (8) with clamps (16) on support (2) with screw (4) and
nut (15).
8. Install three tiedown straps (5) on inlet and outlet hoses (6) and (8).

Ž Install air horn (para. 3-14).
12-96
TM 9-2320-280-20-3
12-67. SWINGFIRE RELAY AND HARNESS ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
M966, M966A1, M996, M996A1, M997, TM 9-2320-280-24P
M997A1, M997A2, M998, M998A1, M1025,
General mechanic’s tool kit: Ž Brushguard and shield assembly removed
Materials/Parts
a. Removal
CAUTION
Use care when removing harness. Failure to do so will cause
damage to harness.
NOTE
1. Remove screw (16) and body wiring harness (17) from bracket (15).
2. Remove two screws (6) and leads 81E (8) and 81B (10) from relay (7).
3. Remove two screws (12) and leads 81B (11) and GND (9) from relay (7).
4. Remove two nuts (5) and relay (7) from bracket (15).
5. Remove two screws (1) and leads 81E (26) and 81B (2) from thermal switch (3).
6. Disconnect lead 81B (18) from connector (20).
7. Disconnect lead 81B (13) from lead 81A (14) and remove harness assembly (4).
8. Remove nipple (19) from lead 81B (18).
9. Remove nut (21), lockwasher (22), and connector (20) from cover (25). Discard lockwasher (22).
Remove grommet (23) from cowl (24).
10.
12-97
TM 9-2320-280-20-3
12-67. SWINGFIRE RELAY AND HARNESS ASSEMBLY REPLACEMENT (Cont’d)

b. Installation
1. Install grommet (23) to cowl (24).

2. Install cover (25) and connector (20) with lockwasher (22) and nut (21).
3. Install nipple (19) on lead 81B (18).
CAUTION
Use care when routing harness. Failure to do so will cause
damage to harness.
4. Install harness assembly (4) inside cowl (24) and connect lead 81B (13) to 81A (14).
5. Route leads 81E (26) and 81B (2) through cowl (24).
6. Connect lead 81B (18) to connector (20).
7. Connect leads 81B (2) and 81E (26) to thermal switch (3) with two screws (1).
8. Install relay (7) on bracket (15) with two nuts (5).
9. Connect leads 81G (11) and GND (9) to relay (7) with two screws (12).
10. Connect leads 81B (10) and 81E (8) to relay (7) with two screws (6).
11. Connect body wiring harness (17) to bracket (15) with screw (16).
FOLLOW-ON TASKS: Ž Install brushguard and shield assembly (para. 12-59).

12-98
TM 9-2320-280-20-3
12-68. SWINGFIRE HEATER HARNESS ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
Seven tiedown straps (Appendix G, Item 239)
M966, M966A1, M996, M996A1, M997,
M1025A1, M1025A2, M1037, M1038, M1038A1
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) Ž Battery ground cable disconnected (para. 4-73).
Ž Air horn removed (para. 3-14).
a. Removal
CAUTION
Use care when removing harness. Failure to do so will cause
damage to harness.
NOTE
1. Remove two screws (9) and disconnect lead 81G (8) and GND (4) from relay (1).
2. Disconnect lead 81A (6) from lead 81B (7).
3. Pull harness assembly (5) out through cowl (2).
4. Remove grommet (3) from cowl (2).
5. Remove three tiedown straps (10) from harness assembly (5) and “A” beam (11). Discard
tiedown straps (10).
6. Remove tiedown strap (14) from harness assembly (5) and air horn bracket (13). Discard
tiedown strap (14).
7. Disconnect lead 81G (8) and GND (4) from heater pump leads (12).
12-99
TM 9-2320-280-20-3
12-68. SWINGFIRE HEATER HARNESS ASSEMBLY REPLACEMENT (Cont’d)

8. Remove three tiedown straps (15) from harness assembly (5) and vent line and right hand
cowl (16). Discard tiedown straps (15).
9. Remove nut (19) from lead GND (4) and negative battery terminal (18) inside battery box (17).
10. Disconnect GND (4) from negative battery terminal (18) and lead 81A (6) from circuit breaker (20).
11. Guide harness assembly (5) out through hole in battery box (17) and remove harness assembly (5)
from vehicle.
b. Installation
CAUTION
Use care when routing harness. Failure to do so will cause damage
to harness.
1. Position harness assembly (5) on right hand cowl (16) along right hand frame rail and vent line and
secure with three tiedown straps (15).
2. Guide harness assembly (5) through hole in battery box (17) and connect lead 81A (6) to circuit
breaker (20) inside battery box (17).
3. Connect GND (4) to negative battery terminal (18) with nut (19).
4. Connect GND (4) and lead 81G (8) to heater pump leads (12).
5. Install harness assembly (5) under air horn bracket (13) with tiedown strap (14).
6. Install harness assembly (5) across “A” beam (11) with three tiedown straps (10).
7. Install grommet (3) to cowl (2).
8. Guide harness assembly (5) through grommet (3).
9. Connect lead 81A (6) to lead 81B (7).
10. Connect GND (4) and lead 81G (8) to relay (1) with two screws (9).
12-100
TM 9-2320-280-20-3
12-68. SWINGFIRE HEATER HARNESS ASSEMBLY REPLACEMENT (Cont’d)

12-101
TM 9-2320-280-20-3
12-69. SWINGFIRE CIRCUIT BREAKER AND HARNESS LEAD REPLACEMENT

This task covers:
INITIAL SETUP:
M966, M966A1, M996, M996A1, M997, Three lockwashers (Appendix G, Item 111)
M1025A1, M1025A2, M1037, M1038, M1038A1
TM 9-2320-280-24P
Tools
NOTE
a. Removal
1. Disconnect harness leads 81A (3) and 81A (4) from circuit breaker (1) inside battery box (9).
2. Remove two nuts (11), lockwashers (10), screws (2), and circuit breaker (1) from battery box (9).
3. Remove nut (7), lockwasher (6), washer (5) and harness lead 81A (3) from power feed through
stud (8). Discard lockwashers (6).
b. Installation
1. Install harness lead 81A (3) on power feed through stud (8) with washer (5), lockwasher (6), and
nut (7).
2. Install circuit breaker (1) on battery box (9) with two screws (2), lockwashers (10), and nuts (11).
3. Connect harness leads 81A (3) and 81A (4) to circuit breaker (1).
12-102
TM 9-2320-280-20-3
12-70. SWINGFIRE WINDSHIELD WASHER PUMP HARNESS EXTENSION REPLACEMENT

This task covers:
INITIAL SETUP:
M966, M966A1, M996, M996A1, M997, TM 9-2320-280-10
M997A1, M997A2, M998, M998A1, M1025, TM 9-2320-280-24P
Materias/Parts
a. Removal
NOTE
1. Remove tiedown strap (8) from harness extension (7) and protective control box wiring
harness (9). Discard tiedown strap (8).
2. Disconnect leads 71C (3) and 57D (6) from windshield washer pump leads 71C (2) and 57D (1).
3. Disconnect leads 71C (3) and 57D (6) from body wiring harness (4) under dash panel.
4. Pull harness extension (7) out through cowl (5) and remove harness extension (7) from vehicle.
b. Installation
1. Guide harness extension (7) through cowl (5).

2. Connect leads 71C (3) and 57D (6) to body wiring harness (4) under dash panel.
3. Connect leads 57D (6) and 71C (3) to windshield washer pump leads 71C (2) and 57D (1).
4. Install harness extension (7) on protective control box wiring harness (9) with tiedown strap (8).

12-103
TM 9-2320-280-20-3
Section V. ARCTIC WINTERIZATION CREW TOP KITS MAINTENANCE
12-71. ARCTIC WINTERIZATION CREW TOP KITS MAINTENANCE TASK SUMMARY
TASK PAGE
PARA. PROCEDURES
NO.
12-72. Arctic Top Cover Assembly Replacement 12-105

12-73. Arctic Curtain Assembly Replacement 12-106
12-74. Arctic Curtain Angle Assembly Replacement 12-107
12-75. Arctic Window Replacement 12-108
12-76. Arctic Curtain Channel Assembly Replacement (2-Man Crew) 12-109
12-77. Arctic Curtain Channel Assembly Replacement (4-Man Crew) 12-110
12-78. Arctic Curtain Fastener Tape Hook Replacement 12-112
12-79. Arctic Foam Insulation Strip Replacement 12-113
12-104
TM 9-2320-280-20-3
12-72. ARCTIC TOP COVER ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
M998, M998A1, M1037, M1038, M1038A1, TM 9-2320-280-24P
M1097, M1097A1, M1097A2
Tools
a. Removal
1. Unfasten eleven turnbuttons (8) from top cover (6) and “B” pillar (7).
2. Unfasten two turnbuttons (9) from top cover flaps (2) and "B" pillar (7).
3. Unfasten six turnbuttons (10) from top cover flaps (2) and horizontal rails (11).
4. Unfasten two turnbuttons (3) from top cover flaps (2) and windshield frame (4).
5. Fold top cover (6) toward front of vehicle and slide front bead (1) of top cover (6) from “A” pillar
former assembly (5) and remove top cover (6).
b. Installation
1. Install top cover (6) by sliding front bead (1) of top cover (6) into “A” pillar former assembly (5).
2. Unfold top cover (6) toward rear of vehicle.
3. Install top cover flaps (2) on horizontal rails (11) with six turnbuttons (10).
4. Install top cover flaps (2) on “B” pillar (7) with two turnbuttons (9).
5. Install top cover (6) on “B” pillar (7) with eleven turnbuttons (8).
6. Install two top cover flaps (2) on windshield frame (4) with two turnbuttons (3).
12-105
TM 9-2320-280-20-3
12-73. ARCTIC CURTAIN ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
M998, M998A1, M1037, M1038, M1038A1, TM 9-2320-280-24P
M1097, M1097A1, M1097A2
Equipment Condition
Tools Ž Companion seat back removed (para. 10-34).

General mechanic’s tool kit: Ž Arctic top cover assembly removed (para. 12-72).
a. Removal
1. Peel curtain (3) back from fastener tape (4) on angle assembly (6).
2. Release two straps (7), remove curtain (3) from channel assembly (8), and peel curtain (3) back from
fastener tape (4) on channel assembly (8).
3. Peel curtain (3) back from fastener tape (4) on tunnel (5) and “B” pillar (1).
4. Unfasten twelve turnbuttons (2) and remove curtain (3) from “B” pillar (1).
b. Installation
1. Install curtain (3) on “B” pillar (1) with twelve turnbuttons (2).
2. Attach curtain (3) to fastener tape (4) on “B” pillar (1) and tunnel (5).
3. Attach curtain (3) to fastener tape (4) on channel assembly (8) with two straps (7).
4. Attach curtain (3) to fastener tape (4) on angle assembly (6).
FOLLOW-ON TASKS: Ž Install arctic top cover assembly (para. 12-72).

Ž Install companion seat back (para. 10-34).
12-106
TM 9-2320-280-20-3
12-74. ARCTIC CURTAIN ANGLE ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
M1097, M1097A1, M1097A2 One assistant
Materials/Parts
Adhesive-sealant (Appendix C, Item 10)
a. Removal
1. Peel curtain (2) back from fastener tape (1) on angle assembly (4).
2. Remove three locknuts (8), washers (9), capscrews (5), washers (6), and angle assembly (4) from
3. Peel fastener tape (1) from angle assembly (4).
4. Clean remaining adhesive from angle assembly (4) surface.
b. Installation
NOTE
backing.
1. Peel paper backing (3) from fastener taps (1) and install fastener tape (1) to angle assembly (4).
2. Install angle assembly (4) on cargo floor (7) with three washers (6), capscrews (5), washers (9), and
locknuts (8). Tighten locknuts (8) to 17 lb-ft (23 NŽm).
3. Attach curtain (2) to fastener tape (1) on angle assembly (4).
12-107
TM 9-2320-280-20-3
12-75. ARCTIC WINDOW REPLACEMENT

This task covers:
INITIAL SETUP:
M1042, M1097, M1097A1, M1097A2 One assistant
Tools
Manual References
Materials/Parts
Adhesive-sealant (Appendix C, Item 10)
Eighteen locknuts (Appendix G, Item 88)
a. Removal
1. Remove eighteen locknuts (1), screws (7), two retainers (2), inner window (3), and outer window (6)
from arctic curtain (4). Discard locknuts (1).
2. Remove adhesive-sealant from edge of outer window (6).
b. Installation
1. Apply adhesive-sealant around edge of outer window (6) between screw holes.
2. Insert outer window (6) into curtain flaps (5), ensuring surface without adhesive-sealant faces
outside of vehicle.
3. Insert inner window (3) into curtain flaps (5) from inside of vehicle, and align inner window (3) and
outer window (6) screw holes.
4. Secure inner window (3) and outer window (6) to arctic curtain flaps (5) with two retainers (2),
eighteen screws (7), and locknuts (1).
12-108
TM 9-2320-280-20-3
12-76. ARCTIC CURTAIN CHANNEL ASSEMBLY REPLACEMENT (2-MAN CREW)

This task covers:
INITIAL SETUP:
M998, M998A1, M1037, M1038, M1038A1, Four locknuts (Appendix G, Item 74)
M1097, M1097A1, M1097A2
Manual References
Tools TM 9-2320-280-24P
a. Removal
1. Peel curtain (13) back from fastener tape (7) on channel assembly (8).
2. Open two straps (1) from curtain (13) and channel assembly (8).
3. Remove four capscrews (4), washers (5), and channel assembly (8) from cargo floor (12).
4. Peel and remove fastener tape (7) from channel assembly (8).
5. Remove seal (9) from channel assembly (8).
6. Remove four locknuts (11), washers (10), screws (3), and two footman loops (2) from channel
b. Installation
NOTE
backing.
1. Install two footman loops (2) on channel assembly (8) with four screws (3), washers (10), and
locknuts (11).
2. Install seal (9) into channel assembly (8).
3. Peel paper backing (6) from fastener tape (7) and install fastener tape (7) on channel assembly (8).
4. Install channel assembly (8) on cargo floor (12) with four washers (5) and capscrews (4).
5. Install curtain (13) on channel assembly (8) with two straps (1).
6. Secure curtain (13) to channel assembly (8) with fastener tape (7).
12-109
TM 9-2320-280-20-3
1 2 - 7 7 . ARCTIC CURTAIN CHANNEL ASSEMBLY MAINTENANCE (4-MAN CREW)
This task covers:

b. Inspection
INITIAL SETUP:
M998, M998A1, M1038, M1038A1, M1097, Eight locknuts (Appendix G, Item 72)
M1097A1, M1097A2, M1123 Four locknuts (Appendix G, Item 94.1)
Ten locknuts (Appendix G, Item 58.1)
Tools
Manual References
a. Removal
1. Release two straps (2) from curtain (3) and wheelhousing channel assemblies (1) and (22).
2. Release four straps (4) from curtain (3) and cargo floor channel assembly (11).
3. Pull curtain (3) back from fastener tape (10) on wheelhousing channel assemblies (1) and (22), and
cargo floor channel assembly (11).
4. Remove six capscrews (8), washers (9), and cargo floor channel assembly (11) from cargo floor (14).
5. Remove seal (12) from cargo floor channel assembly (11).
6. Remove eight locknuts (13), washers (12.1), screws (7), and four footman loops (6) from cargo floor
channel assembly (11). Discard locknuts (13).
7. Remove ten locknuts (21), twenty washers (16), ten capscrews (15), and wheelhousing channel
assemblies (1) and (22) from wheelhousings (20). Discard locknuts (21).
8. Remove four locknuts (19), screws (17), and two footman loops (18) from wheelhousing channel
assemblies (1) and (22). Discard locknuts (19).
b. Inspection
1. Inspect thirty-one turnbuttons (23) on soft top for bends, corrosion, or damage. Replace if bent,
corroded, or damaged (refer to para. 10-66).
2. Inspect six rivnuts (5) on cargo floor for looseness, cracks, wearing, or damage. Replace if loose,
cracked, worn, or damaged (refer to para. 10-66).
3. Inspect fastener tape (10) on wheelhousing channel assemblies (1) and (22) and cargo floor channel
assembly (11) for tearing or damage. Replace if torn or damaged (refer to para. 12-78).
c. Installation
1. Install two footman loops (18) on wheelhousing channel assemblies (1) and (22) with four screws (17)
and locknuts (19).
2. Install wheelhousing channel assemblies (1) and (22) on wheelhousings (20) with twenty washers (16),
ten capscrews (15), and locknuts (21).
3. Install four footman loops (6) on cargo floor channel assembly (11) with eight screws (7), washers (12.1),
and locknuts (13).
4. Install seal (12) in cargo floor channel assembly (11).
5. Install cargo floor channel assembly (11) on cargo floor (14) with six washers (9) and capscrews (8).
6. Install curtain (3) on wheelhousing channel assemblies (1) and (22) and cargo floor channel
assembly (11) with fastener tape (10).
7. Secure curtain (3) to cargo floor channel assembly (11) with four straps (4).
8. Secure curtain (3) to wheelhousing channel assemblies (1) and (22) with two straps (2).
12-110 Change 1
TM 9-2320-280-20-3
12-77. ARCTIC CURTAIN CHANNEL ASSEMBLY REPLACEMENT (4-MAN CREW)

(Cont’d)
Change 1 12-111
TM 9-2320-280-20-3
12-78. ARCTIC CURTAIN FASTENER TAPE HOOK REPLACEMENT

This task covers:
INITIAL SETUP:
M998, M998A1, M1037, M1038, M1038A1, TM 9-2320-280-24P
M1097, M1097A1, M1097A2
Equipment Condition
Tools Arctic curtain assembly removed (para. 12-73).
NOTE
All fastener tape is removed and installed the same. This
procedure covers the “B” pillar fastener tape.
a. Removal
1. Peel fastener tape (3) from “B” pillar (2).

2. Clean remaining adhesive from “B” pillar (2).
b. Installation
1. Ensure “B” pillar surface (2) is free of dirt and oil.

2. Peel paper backing (1) from fastener tape (3).
3. Apply fastener tape (3) to “B” pillar (2) and press firmly in place.
FOLLOW-ON TASK: Install arctic curtain assembly (para. 12-73).
12-112
TM 9-2320-280-20-3
12-79. ARCTIC FOAM INSULATION STRIP REPLACEMENT

This task covers:
INITIAL SETUP:
M998, M998A1, M1037, M1038, M1038A1, TM 9-2320-280-24P
M1097, M1097A1, M1097A2
Tools
a. Removal
1. Peel foam insulation strip (3) from “A” pillar (1).

2. Clean remaining adhesive from “A” pillar surface (1).
b. Installation
NOTE
Ensure “A” pillar surface is free of dirt and oil before applying
foam insulation strip.
1. Peel paper backing (2) from foam insulation strip (3).
2. Install foam insulation strip (3) on “A n pillar (1) and press firmly in place.
12-113
TM 9-2320-280-20-3
Section VI. TROOP/CARGO WINTERIZATION KIT MAINTENANCE
12-80. TROOP/CARGO WINTERIZATION KIT MAINTENANCE TASK SUMMARY

PARA. NO.
12-81. Troop/Cargo Winterization Heater Fuel Pump Replacement 12-116

12-82. Troop/Cargo Winterization Heater Fuel Filter Assembly 12-119
Replacement
12-83. Troop/Cargo Winterization Heater Fuel Supply Tube 12-121
Assembly Replacement
12-84. Troop/Cargo Winterization Heater Tank-to-Hose Fuel Supply 12-122
Line Replacement
12-85. Troop/Cargo Winterization Heater Fuel Supply Hose Replacement 12-123
12-86. Troop/Cargo Winterization Heater Pump-to-Hose Fuel Supply 12-124
Line Replacement
12-87. Troop/Cargo Winterization Heater Pump-to-Bulkhead Fuel 12-125
Supply Line Replacement
12-88. Troop/Cargo Winterization Heater Bulkhead Fuel Supply 12-127
Hose Replacement
12-89. Troop/Cargo Winterization Heater Bulkhead Hose-to-Bulkhead 12-128
Coupling Fuel Supply Line Replacement
12-90. Troop/Cargo Winterization Heater Fuel Supply Line Bulkhead 12-129
Coupling Replacement
12-91. Troop/Cargo Winterization Heater Filter-to-Bulkhead Coupling 12-131
Fuel Supply Hose Replacement
12-92. Troop/Cargo Winterization Heater Filter-to-Heater Fuel Supply 12-133
Hose Replacement
12-93. Troop/Cargo Winterization Heater Guard Assembly Replacement 12-135
12-94. Troop/Cargo Winterization Heat Deflector Replacement 12-136
12-95. Troop/Cargo Winterization Heater Assembly Replacement 12-137
12-96. Troop/Cargo Winterization Heater Diverter Assembly Replacement 12-140
12-97. Troop/Cargo Winterization Heater Air Intake Assembly 12-141
Replacement
12-98. Troop/Cargo Winterization Heater Base Assembly Replacement 12-142
12-99. Troop/Cargo Winterization Floor Bracket Replacement 12-143
12-100. Troop/Cargo Winterization Heater Control Box and Angle 12-144
Bracket Replacement
12-101. Troop/Cargo Winterization Heater Wiring Harness Replacement 12-146
12-102. Troop/Cargo Winterization Heater Wiring Harness Adapter 12-150
Replacement
12-103. Troop/Cargo Winterization Circuit Breaker Replacement 12-152
12-104. Troop/Cargo Winterization Blackout Curtain Replacement 12-153
12-105. Troop/Cargo Winterization Blackout/Dome Light Wiring 12-154
Harness Replacement
12-114
TM 9-2320-280-20-3
12-80. TROOP/CARGO WINTERIZATION KIT MAINTENANCE TASK SUMMARY

(Cont’d)
TASK PAGE
PARA. PROCEDURES
NO.
12-106. Troop/Cargo Winterization Blackout/Dome Light Switch 12-156

Replacement
12-107. Troop/Cargo Winterization Blackout/Dome Light Door Switch 12-158
Replacement
12-108. Troop/Cargo Winterization Blackout/Dome Light Assembly 12-160
Replacement
12-109. Troop/Cargo Winterization Blackout/Dome Light Lamp 12-161
Replacement
12-110. Troop/Cargo Winterization Front and Rear Cargo Floor Cover 12-162
Replacement
12-111. Troop/Cargo Winterization Cargo Floor Skid Strips Replacement 12-164
12-112. Troop/Cargo Winterization Seat Back Cover Replacement 12-165
12-113. Troop/Cargo Winterization Fixed Door Cover Replacement 12-166
12-114. Troop/Cargo Winterization Side Floor Cover Replacement 12-167
12-115. Troop/Cargo Winterization Wheelhousing Covers Replacement 12-168
12-116. Troop/Cargo Winterization Door Adjustment 12-170
12-117. Troop/Cargo Winterization Door and Frame Assembly Replacement 12-172
12-118. Troop/Cargo Winterization End Closure Replacement 12-176
12-119. Troop/Cargo Winterization Top Cover Assembly Replacement 12-180
12-120. Troop/Cargo Winterization Top Enclosure Assembly Replacement 12-186
12-121. Troop/Cargo Winterization Troop Seat Assembly and Bow 12-190
Replacement
12-122. Troop/Cargo Winterization Rear Step Assembly Replacement 12-194
12-123. Troop/Cargo Winterization Handle Assembly Replacement 12-195
12-124. Troop/Cargo Winterization Fuel Can Mounting Bracket 12-196
Replacement
12-125. Troop/Cargo Winterization Antenna Mounting Bracket 12-197
Replacement
12-126. Troop/Cargo Winterization Rear Reflector Replacement 12-198
12-127. Troop/Cargo Winterization Rear Composite Light Housing 12-199
Replacement
12-128. Troop/Cargo Winterization Data Plate Replacement 12-200
12-115
TM 9-2320-280-20-3
12-81. TROOP/CARGO WINTERIZATION HEATER FUEL PUMP REPLACEMENT

This task covers:
lNITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
Two locknuts (Appendix G, Item 58) or sparks.
WARNING
a. Removal
CAUTION
disconnection to prevent contamination. Remove all plugs prior
to connection.
NOTE
Ž Have drainage container ready to catch fuel.
Ž Prior to removal, tag leads for installation.
1. Disconnect fuel pump lead (2) from electrical connector (3).
2. Disconnect pumo-to-hose fuel supply line (6) from connector (7).
3. Remove connector (7) from fuel pump (1).
NOTE
Perform step 5 if vehicle is equipped with front arctic heater.
Perform step 6 if vehicle is not equipped with front arctic heater.
5. Disconnect arctic heater fuel supply line (5) from connector (4).
6. Remove cap (11) from connector (4).
7. Remove two locknuts (15), washers (14), lockwasher (12), two capscrews (17), washers (14), fuel
pump (1), and ground lead 799B (13) from bracket (16). Discard locknuts (15) and
lockwasher (12).
NOTE
8. Inspect four rivets (19) on bracket (16) and crossmember (18) and replace rivets (19),
if damaged.
9. Remove connectors (9) and (4) and tee (10) from fuel pump (1).
12-116
TM 9-2320-280-20-3
12-81. TROOP/CARGO WINTERIZATION HEATER FUEL PUMP REPLACEMENT (Cont’d)
12-117
TM 9-2320-280-20-3
12-81. TROOP/CARGO WINTERIZATION HEATER FUEL PUMP REPLACEMENT (Cont’d)

b. Installation
1. Apply sealing compound to threads of connectors (9) and (4) and install connectors (9) and (4)
on tee (10).
2. Apply sealing compound to threads of fuel pump (1) and install connector (7) and tee (10) on fuel
pump (1).
3. Install fuel pump (1) and ground lead 799B (13) on bracket (16) with two washers (14),
capscrews (17), lockwasher (12), two washers (14), and locknuts (15).
4. Apply sealing compound to threads of connector (9) and connect pump-to-bulkhead fuel supply
line (8) to connector (9).
NOTE
5. Apply sealing compound to threads of connector (4) and connect arctic heater fuel supply line (5)
to connector (4).
6. Apply sealing compound to threads of connector (4) and install cap (11) on connector (4).
7. Apply sealing compound to threads of connector (7) and connect pump-to-hose fuel supply line (6)
to connector (7).
8. Connect fuel pump lead (2) to electrical connector (3).
FOLLOW-ON TASKS: Ž Connect battery ground cable (para. 4-73).

Ž Operate troop/cargo heater (TM 9-2320-280-10) and check for fuel leaks.
12-118
TM 9-2320-280-20-3
12-82. TROOP/CARGO WINTERIZATION HEATER FUEL FILTER ASSEMBLY

REPLACEMENT
This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) Heater guard assembly removed
(para. 12-93).
Materials/Parts
Sealing compound (Appendix C, Item 44) General Safety Instructions
Two locknuts (Appendix G, Item 94) Do not perform this procedure near fire, flames,
or sparks.
WARNING
a. Removal
CAUTION
connection.
NOTE
1. Loosen clamp (3) and disconnect filter-to-heater fuel supply hose (2) from filter elbow (4).
2. Loosen clamp (9) and disconnect filter-to-bulkhead coupling fuel supply hose (8) from filter
connector (10).
3. Remove two locknuts (1) and capscrews (7) from filter assembly (5), spacers (11), and heater base
4. Remove filter elbow (4) and connector (10) from filter assembly (5).
12-119
TM 9-2320-280-20-3
12-82. TROOP/CARGO WINTERIZATION HEATER FUEL FILTER ASSEMBLY

b. Installation
1. Apply sealing compound to threads of filter elbow (4) and connector (10) and install filter elbow (4)
and connector (10) on filter assembly (5).
2. Install two spacers (11) and filter assembly (5) on heater base assembly (6) with two capscrews (7)
and locknuts (1).
3. Connect filter-to-bulkhead coupling fuel supply hose (8) to filter connector (10) with clamp (9).
4. Connect filter-to-heater fuel supply hose (2) to filter elbow (4) with clamp (3).
FOLLOW-ON TASKS: Ž Install heater guard assembly (para. 12-93).

12-120
TM 9-2320-280-20-3
12-83. TROOP/CARGO WINTERIZATION HEATER FUEL SUPPLY TUBE ASSEMBLY

REPLACEMENT
This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) Fuel tank removed (para. 3-24).
or spar .
WARNING
near firs, flames, or sparks. Severe injury or death will result.
a. Removal
1. Mark position of fuel supply tube assembly (2) on access cover (3).
CAUTION
connection.
NOTE
2. Disconnect tank-to-hose fuel supply line (4) from fuel supply tube assembly (2).
3. Remove fuel supply tubs assembly (2) from fuel tank (1).
b. Installation
1. Apply sealing compound to threads of fuel supply tube assembly (2) and install tube assembly (2) on
fuel tank (1).
2. Apply sealing compound to tank-to-hose fuel supply line (4) and connect fuel supply line (4) to fuel
supply tube assembly (2).

12-121
TM 9-2320-280-20-3
12-84. TROOP/CARGO WINTERIZATION HEATER TANK-TO-HOSE FUEL SUPPLY LINE

REPLACEMENT
This task covers:
lNITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) Fuel tank removed (para. 3-24).
or sparks.
WARNING
a. Removal
CAUTION
connection.
NOTE
1. Disconnect tank-to-hose fuel supply line (3) from tube assembly (2).
2. Remove capscrew (4), clamp (5), and tank-to-hose fuel supply line (3) from fuel tank (1).
b. Installation
1. Apply sealing compound to threads of tank-to-hose fuel supply line (3) and connect tank-to-hose
fuel supply line (3) to tube assembly (2).
2. Install tank-to-hose fuel supply line (3) on fuel tank (1) with clamp (5) and capscrew (4).
12-122
TM 9-2320-280-20-3
12-85. TROOP/CARGO WINTERIZATION HEATER FUEL SUPPLY HOSE REPLACEMENT

This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
General mechanic’s tool kit: General Safety Instructions
or sparks.
WARNING
a. Removal
CAUTION
connection.
NOTE
Remove two clamps (4) and fuel supply hose (3) from tank-to-hose fuel supply line (2) and pump-to-hose
fuel supply line (1).
b. Installation
1. Connect fuel supply hose (3) to tank-to-hose fuel supply line (2) with clamp (4).
FOLLOW-ON TASK: Operate troop/cargo heater (TM 9-2320-280-10) and check for fuel leaks.
12-123
TM 9-2320-280-20-3
12-86. TROOP/CARGO WINTERIZATION HEATER PUMP-TO-HOSE FUEL SUPPLY LINE

REPLACEMENT
This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
or sparks.
Materials/Parts
WARNING
a. Removal
CAUTION
to connection.
NOTE
1. Loosen clamp (5) and disconnect fuel supply hose (4) from pump-to-hose fuel supply line (3).
2. Disconnect pump-to-hose fuel supply line (3) from connector (2) on fuel pump (1).
3. Inspect connector (2) for damaged threads or cracks. Replace if cracked or damaged.
b. Installation
1. Apply sealing compound to threads of connector (2) and connect pump-to-hose fuel supply line (3)
to connector (2) on fuel pump (1).
12-124
TM 9-2320-280-20-3
12-87. TROOP/CARGO WINTERIZATION HEATER PUMP-TO-BULKHEAD FUEL SUPPLY

LINE REPLACEMENT
This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-10
Tools
TM 9-2320-280-24P

Materials/Parts
or sparks.
WARNING
a. Removal
CAUTION
to connection.
NOTE
2. Remove clamp (5) and bulkhead hose (4) from pump-to-bulkhead fuel supply line (3).
NOTE
If vehicle is equipped with front arctic heater unit, cap will not be
installed on connector.
3. Inspect connector (2), tee (1), connector (6), and cap (7) for damaged threads or cracks. Replace
if cracked or damaged
12-125
TM 9-2320-280-20-3
12-87. TROOP/CARGO WINTERIZATION HEATER PUMP-TO-BULKHEAD FUEL SUPPLY

LINE REPLACEMENT (Cont’d)
b. Installation
1. Connect bulkhead hose (4) to pump-to-bulkhead fuel supply line (3) with clamp (5).
2. Apply sealing compound to threads of connector (2) on tee (1) and connect pump-to-bulkhead fuel
supply line (3) to connector (2).
12-126
TM 9-2320-280-20-3
12-88. TROOP/CARGO WINTERIZATION HEATER BULKHEAD FUEL SUPPLY HOSE

REPLACEMENT
This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
or sparks.
WARNING
a. Removal
CAUTION
to connection.
NOTE
Remove two clamps (2) and bulkhead fuel supply hose (4) from pump-to-bulkhead fuel supply line (1) and
bulkhead hose-to-bulkhead coupling supply line (3).
b. Installation
Connect bulkhead fuel supply hose (4) to pump-to-bulkhead fuel supply line (1) and bulkhead hose-to-
bulkhead coupling supply line (3) with two clamps (2).
12-127
TM 9-2320-280-20-3
12-89. TROOP/CARGO WINTERIZATION HEATER BULKHEAD HOSE-TO-BULKHEAD

COUPLING FUEL SUPPLY LINE REPLACEMENT
This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
or sparks.
Materials/Parts
WARNING
a. Removal
CAUTION
to connection.
NOTE
1. Loosen clamp (2) and disconnect bulkhead hose (1) from bulkhead hose-to-bulkhead coupling fuel
supply line (3).
2. Disconnect bulkhead hose-to-bulkhead coupling fuel supply line (3) from elbow (4) and remove
bulkhead hose-to-bulkhead coupling fuel supply line (3).
b. Installation
1. Apply sealing compound to threads of elbow (4) and connect bulkhead hose-to-bulkhead coupling
fuel supply line (3) to elbow (4).
2. Connect bulkhead hose (1) to bulkhead hose-to-bulkhead coupling fuel supply line (3) with clamp (2).
12-128
TM 9-2320-280-20-3
12-90. TROOP/CARGO WINTERIZATION HEATER FUEL SUPPLY LINE BULKHEAD

COUPLING REPLACEMENT
This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
or sparks.
Materials/Parts
WARNING
a. Removal
CAUTION
to connection.
NOTE
1. Disconnect bulkhead hose-to-bulkhead coupling fuel supply line (7) from elbow (8).
2. Remove elbow (8) from nipple (9).
3. Remove nut (10) and washers (11) and (6) from coupling half (12) and cargo floor (5).
4. Pull remaining fittings up through cargo floor (5).
5. Loosen clamp (1) and disconnect filter-to-bulkhead coupling fuel supply hose (2) from connector (3).
6. Remove connector (3) from adapter (4).
7. Remove adapter (4) from coupling half (12).
8. Remove nipple (9) from coupling half (12).
12-129
TM 9-2320-280-20-3
12-90. TROOP/CARGO WINTERIZATION HEATER FUEL SUPPLY LINE BULKHEAD

COUPLING REPLACEMENT (Cont’d)
b. Installation
1. Apply sealing compound to threads of nipple (9) and install nipple (9) on coupling half (12).
2. Apply sealing compound to threads of adapter (4) and install adapter (4) on coupling half (12).
3. Apply sealing compound to threads of connector (3) and install connector (3) on adapter (4).
4. Connect filter-to-bulkhead coupling fuel supply hose (2) to connector (3) with clamp (1).
5. Insert nipple (9), coupling half (12), adapter (4), and connector (3) through cargo floor (5).
6. Secure coupling half (12) to cargo floor (5) with washers (6) and (11) and nut (10).
7. Apply sealing compound to threads of nipple (9) and install elbow (8) on nipple (9).
8. Apply sealing compound to threads of elbow (8) and connect bulkhead hose-to-bulkhead
coupling fuel supply line (7) to elbow (8).
12-130
TM 9-2320-280-20-3
12-91. TROOP/CARGO WINTERIZATION HEATER FILTER-TO-BULKHEAD COUPLING

FUEL SUPPLY HOSE REPLACEMENT
This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
(para. 12-93).
Materials/Parts
Do not perform this procedure near tire, flames,
or sparks.
WARNING
a. Removal
CAUTION
connection.
NOTE
1. Loosen clamp (2) and disconnect filter-to-bulkhead coupling fuel supply hose (1) from filter
connector (3).
2. Loosen clamp (4) and remove filter-to-bulkhead coupling fuel supply hose (1) from bulkhead coupling
connector (5).
3. Inspect filter connector (3) and bulkhead coupling connector (5) for damage. Replace if cracked
or damaged.
12-131
TM 9-2320-280-20-3
12-91. TROOP/CARGO WINTERIZATION HEATER FILTER-TO-BULKHEAD COUPLING

FUEL SUPPLY HOSE REPLACEMENT (Cont’d)
b. Installation
1. Connect filter-to-bulkhead coupling fuel supply hose (1) to bulkhead coupling connector (5) with
clamp (4).
2. Connect filter-to-bulkhead coupling fuel supply hose (1) to filter connector (3) with clamp (2).

12-132
TM 9-2320-280-20-3
12-92. TROOP/CARGO WINTERIZATION HEATER FILTER-TO-HEATER FUEL SUPPLY

HOSE REPLACEMENT
This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
General mechanic’s tool kit: Equipment Conditon
(para. 12-93).
Materials/Parts
Do not perform this procedure near fire, flames,
or sparks.
WARNING
a. Removal
CAUTION
connection.
NOTE
1. Loosen clamp (4) and disconnect filter-to-heater fuel supply hose (1) from filter elbow (5).
2. Loosen clamp (2) and disconnect filter-to-heater fuel supply hose (1) from heater connector (3).
3. Inspect filter elbow (5) and heater connector (3) for damage. Replace if damaged.
12-133
TM 9-2320-280-20-3
12-92. TROOP/CARGO WINTERIZATION HEATER FILTER-TO-HEATER FUEL SUPPLY

HOSE REPLACEMENT (Cont’dl
b. Installation
1. Connect filter-to-heater fuel supply hose (1) to heater connector (3) with clamp (2).
2. Install filter-to-heater fuel supply hose (1) on filter elbow (5) with clamp (4).

12-134
TM 9-2320-280-20-3
12-93. TROOP/CARGO WINTERIZATION HEATER GUARD ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 Four lockwashers (Appendix G, Item 118)
a. Removal
Remove four capscrews (3), lockwashers (2), and guard assembly (1) from heater base assembly (4).
b. Installation
Install guard assembly (1) on heater base assembly (4) with four lockwashers (2) and capscrews (3).
12-135
TM 9-2320-280-20-3
12-94. TROOP/CARGO WINTERIZATION HEAT DEFLECTOR REPLACEMENT

This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-24P
General mechanic’s tool kit: Heater guard assembly removed (para. 12-93).
Materials/Parts
a. Removal
Remove four capscrews (3), lockwashers (4), and heat deflector (1) from heater base assembly (2). Discard
lockwashers (4).
b. Installation
Install heat deflector (1) on heater base assembly (2) with four lockwashers (4) and capscrews (3).
FOLLOW-ON TASK: Install heater guard assembly (para. 12-93).
12-136
TM 9-2320-280-20-3
12-95. TROOP/CARGO WINTERIZATION HEATER ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
Equipment Condition
automotive (Appendix B, Item 1) Ž Battery ground cable disconnected (para. 4-73).
Ž Heater guard assembly removed (para. 12-93).
Materials/Parts
Adhesive sealant (Appendix C, Item 10) General Safety Instructions
Sealing compound (Appendix C, Item 42) Ž Do not perform this procedure near fire, flames
Seal (Appendix G, Item 219) or sparks.
Ž Ensure handle on diverter assembly is facing
toward left side of vehicle.
WARNING
a. Removal
CAUTION
to connection.
NOTE
1. Loosen clamp (2) and disconnect filter-to-heater fuel supply hose (1) from connector (3).
2. Remove connector (3) from heater inlet port (4).
3. Remove clamp (6) and diverter assembly (7) from air inlet adapter (5).
12-137
TM 9-2320-280-20-3
12-95. TROOP/CARGO WINTERIZATION HEATER ASSEMBLY REPLACEMENT (Cont’d)
4. Disconnect cannon plug (2) from heater (3).

5. Remove two clamps (1) and heater (3) from heater base assembly (4).
6. Remove air inlet adapter (5) from heater (3).
7. Remove seal (6) and washer (7) from heater (3). Discard seal (6).
8. Remove exhaust extension (8) from heater base assembly (4).
b. Installation
NOTE
When installing exhaust extension into heater base assembly,
ensure tab on exhaust extension and notch in heater base
assembly are aligned.
1. Apply sealant to underside surface of flange on exhaust extension (8), and install exhaust
extension (8) on heater base assembly (4).
2. Install washer (7) and seal (6) on heater (3).
3. Install air inlet adapter (5) on heater (3).
4. Install heater (3) on heater base assembly (4) with two clamps (1).
5. Connect cannon plug (2) to heater (3).
WARNING
Ensure handle on diverter assembly is facing toward left side of
vehicle. Improper installation of the diverter assembly may cause
serious injury to personnel.
6. Install diverter assembly (10) on air inlet adapter (5) with clamp (9).
7. Apply sealing compound to threads of connector (13) and install connector (13) on heater
inlet port (14).
8. Connect filter-to-heater fuel supply hose (11) to connector (13) with clamp (12).
12-138
TM 9-2320-280-20-3
12-95. TROOP/CARGO WINTERIZATION HEATER ASSEMBLY REPLACEMENT (Cont’d)

12-139
TM 9-2320-280-20-3
12-96. TROOP/CARGO WINTERIZATION HEATER DIVERTER ASSEMBLY

REPLACEMENT
This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-24P
General mechanic’s tool kit: Ensure handle on diverter assembly is facing
automotive (Appendix B, Item 1) toward left side of vehicle.
a. Removal
1. Remove clamp (2) and flex duct (3) from diverter assembly (1).
2. Remove clamp (5) and diverter assembly (1) from air inlet adapter (4).
b. Installation
WARNING
Ensure handle on diverter assembly is facing toward left side of
vehicle. Improper installation of the diverter assembly may cause
serious injury to personnel.
1. Install diverter assembly (1) on air inlet adapter (4) with clamp (5).
2. Install flex duct (3) on diverter assembly (1) with clamp (2).
12-140
TM 9-2320-280-20-3
12-97. TROOP/CARGO WINTERIZATION HEATER AIR INTAKE ASSEMBLY

REPLACEMENT
This task covers:
lNITIAL SETUP:
M998, M998A1, M1038, M1038A1 Three locknuts (Appendix G, Item 64)
Tools
a. Removal
1. Remove two clamps (9) and flex duct (11) from diverter assembly (10) and adapter (7).
2. Remove three locknuts (5), capscrews (3), and hood (2), from top cover assembly (1) and plate (4).
3. Remove four locknuts (8), screws (12), adapter (7), and screen (6) from plate (4). Discard locknuts (8).
b. Installation
1. Install screen (6) and adapter (7) on plate (4) with four screws (12) and locknuts (8).
2. Install hood (2) on top cover assembly (1) and plate (4) with three capscrews (3) and locknuts (5).
3. Install flex duct (11) on adapter (7) and diverter assembly (10) with two clamps (9).
12-141
TM 9-2320-280-20-3
12-98. TROOP/CARGO WINTERIZATION HEATER BASE ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-24P
General mechanic’s tool kit: Ž Heater assembly removed (para. 12-95).
automotive (Appendix B, Item 1) Ž Heater fuel filter assembly removed
(para. 12-82).
Materials/Parts Ž Heat deflector removed (para. 12-94).
a. Removal
1. Remove six capscrews (2), lockwashers (1), and heater base assembly (3) from cargo floor cover (4).
2. Remove gasket (5) from heater base assembly (3). Discard gasket (5).
b. Installation
1. Install gasket (5) on heater base assembly (3).

2. Install heater base assembly (3) on cargo floor cover (4) with six lockwashers (1) and capscrews (2).
FOLLOW-ON TASKS: Ž Install heat deflector (para. 12-94).

Ž Install fuel filter assembly (para. 12-82).
Ž Install heater assembly (para. 12-95).
12-142
TM 9-2320-280-20-3
12-99. TROOP/CARGO WINTERIZATION FLOOR BRACKET REPLACEMENT

This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-24P
Tools
a. Removal
Remove eight screws (2) and floor bracket (1) from front cargo floor cover (3).
b. Installation
Install floor bracket (1) on front cargo floor cover (3) with eight screws (2).
12-143
TM 9-2320-280-20-3
12-100. TROOP/CARGO WINTERIZATION HEATER CONTROL BOX AND ANGLE

BRACKET REPLACEMENT
This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
Materials/Parts

a. Removal
1. Disconnect control box lead 400 (7) from harness lead 1C (8).
2. Remove tiedown strap (6) from ground lead 2C (3), ground lead (2), control box lead 400 (7), and
heater wiring harness (10). Discard tiedown strap (6).
3. Disconnect cannon plug (11) from inner shell (13).
4. Remove two screws (12) and control box inner shell (13) from outer shell (14),
5. Remove two crown nuts (4), nuts (5), lockwashers (1), capscrews (9), ground lead 2C (3), ground
lead (2), and outer shell (14) from angle bracket (15). Discard lockwashers (1).
6. Remove two locknuts (18), washers (17), capscrews (19), and angle bracket (15) from cargo
bulkhead (16). Discard locknuts (18).
b. Installation
1. Install angle bracket (15) on cargo bulkhead (16) with two capscrews (19), washers (17), and
locknuts (18).
2. Install outer shell (14), ground lead (2), and ground lead 2C (3) to angle bracket (15) with two
capscrews (9), lockwashers (1), and nuts (5).
3. Apply adhesive to exposed threads of two capscrews (9) and install two crown nuts (4) on
capscrews (9).
4. Install inner shell (13) on outer shell (14) with two screws (12).
5. Connect cannon plug (11) to inner shell (13).
6. Connect control box lead 400 (7) to harness lead 1C (8).
7. Install tiedown strap (6) on ground lead 2C (3), ground lead (2), control box lead 400 (7), and heater
wiring harness (10).
12-144
TM 9-2320-280-20-3
12-100. TROOP/CARGO WINTERIZATION HEATER CONTROL BOX AND ANGLE

BRACKET REPLACEMENT (Cont’d)

Ž Check for proper operation of troop/cargo heater (TM 9-2320-280-10).
12-145
TM 9-2320-280-20-3
12-101. TROOP/CARGO WINTERIZATION HEATER WIRING HARNESS REPLACEMENT

This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
Equipment Condition
Materials/Parts
Two tiedown straps (Appendix G, Item 243)
a. Removal
NOTE
Ž Depending on what kits are installed on the vehicle, there may
be unidentified leads on the shunt stud and power stud. These
leads must remain on the studs.
1. Remove nut (6), lockwasher (7), fuel pump ground lead 799B (10) and lead 2A (8) from shunt
stud (9). Discard lockwasher (7).
2. Remove nut (15), lockwasher (14), starter cable (13), and lead 1A (12) from power stud (11). Discard
lockwasher (14).
3. Disconnect lead FP (1) from adapter (2).
4. Remove tiedown strap (4) and heater wiring harness (3) from transmission vacuum line (5). Discard
tiedown strap (4).
5. Disconnect cannon plug (25) from control box inner shell (27).
6. Remove two screws (26) and control box inner shell (27) from outer shell (28).
7. Remove crown nut (19), nut (20), lockwasher (16), capscrew (24), ground lead 2C (18), and ground
lead (17) from angle bracket (29). Discard lockwasher (16).
8. Disconnect lead 1C (23) from control box lead 400 (22).
9. Remove tiedown strap (21) from ground lead 2C (18), ground lead (17), control box lead 400 (22), and
heater wiring harness (3). Discard tiedown strap (21).
10. Disconnect lead 2B (31) from lead 2A (30).
11. Disconnect lead 1B (36) from circuit breaker (35).
12. Disconnect cannon plug (32) from heater (33) and remove heater wiring harness (3).
13. Remove plastic sleeve (34) from heater wiring harness (3).
12-146
TM 9-2320-280-20-3

(Cont’d)
12-147
TM 9-2320-280-20-3

(Cont’d)
b. Installation
1. Install heater wiring harness (3) through cargo floor (7), and position plastic sleeve (6) around
harness (3). Insert plastic sleeve (6) into cargo floor (7).
2. Connect cannon plug (4) to heater (5).
3. Connect lead 1B (9) to circuit breaker (8).
4. Connect lead 2B (2) to lead 2A (1).
5. Connect lead 1C (17) to control box lead 400 (16).
6. Install ground lead (11) and ground lead 2C (12) on angle bracket (23) with capscrew (18),
lockwasher (10), and nut (14).
7. Apply adhesive to exposed threads of capscrew (18) and install crown nut (13) on capscrew (18).
8. Install control box inner shell (21) on outer shell (22) with two screws (20).
9. Connect cannon plug (19) to control box inner shell (21).
10. Install tiedown strap (15) on ground lead 2C (12), ground lead (11), control box lead 400 (16), and
heater wiring harness (3).
11. Connect lead FP (24) to adapter (25).
12. Install lead 1A (34) and starter cable (35) on power stud (33) with lockwasher (36) and nut (37).
13. Install lead 2A (30) and fuel pump ground lead 799B (32) on shunt stud (31) with lockwasher (29)
and nut (28).
14. Install heater wiring harness (3) to transmission vacuum line (27) with tiedown strap (26).
12-148
TM 9-2320-280-20-3

(Cont’d)

12-149
TM 9-2320-280-20-3
12-102. TROOP/CARGO WINTERIZATION HEATER WIRING HARNESS ADAPTER

REPLACEMENT
This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
Materials/Parts
a. Removal
1. Disconnect fuel pump lead (11) from connector (5).

2. Disconnect connector (5) from adapter (4).
3. Disconnect lead FP (1) from adapter (4).
NOTE
4. Disconnect fuel pump jumper lead (6) from adapter (4).
5. Disconnect plug (2) and plug shell (3) from adapter (4).
6. Remove locknut (13), washer (14), capscrew (9), washer(8), fuel pump (10), clamp (12), and
adapter (4) from bracket (7). Discard locknut (13).
7. Remove clamp (12) from adapter (4).
b. Installation
1. Install clamp (12) on adapter (4).

2. Install fuel pump (10), clamp (12), and adapter (4) on bracket (7) with washer (8), capscrew (9),
NOTE
3. Connect fuel pump jumper lead (6) to adapter (4).
4. Connect plug shell (3) and plug (2) to adapter (4).
5. Connect lead FP (1) to adapter (4).
6. Connect connector (5) to adapter (4).
7. Connect fuel pump lead (11) to connector (5).
12-150
TM 9-2320-280-20-3
12-102. TROOP/CARGO WINTERIZATION HEATER WIRING HARNESS ADAPTER


12-151
TM 9-2320-280-20-3
12-103. TROOP/CARGO WINTERIZATION CIRCUIT BREAKER REPLACEMENT
This task covers:

INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
NOTE
a. Removal
1. Disconnect heater harness lead 1B (2) from circuit breaker (4).

2. Disconnect blackout/dome light harness lead 1A (1) from circuit breaker (4).
3. Remove two screws (3) and circuit breaker (4) from front cargo floor cover (5).
b. Installation
1. Install circuit breaker (4) on front cargo floor cover (5) with two screws (3).
2. Connect blackout/dome light harness lead 1A (1) to circuit breaker (4).
3. Connect heater harness lead 1B (2) to circuit breaker (4).

12-152
TM 9-2320-280-20-3
12-104. TROOP/CARGO WINTERIZATION BLACKOUT CURTAIN REPLACEMENT
This task covers:

lNITIAL SETUP:
M998, M998A1, M1038, M1038A1 Eighteen locknuts (Appendix G, Item 82)
NOTE
There are two blackout curtains located in the driver’s compartment
There is also a blackout curtain located above the driver’s compart-
ment on the troop/cargo enclosure assembly. This blackout curtain
opena from inside the enclosure assembly. The replacement proce-
“ are basically the same. The following
dures for all blackout curtains
replacement instructions cover the right blackout curtain in the
driver’s compartment.
a. Removal
Remove eighteen locknuts (2), blackout curtain (3), and retainer (1) from arctic curtain (4). Discard
locknuts (2).
b. Installation
Install blackout curtain (3) and retainer (1) on arctic curtain (4) with eighteen locknuts (2).
12-153
TM 9-2320-280-20-3
12-105. TROOP/CARGO WINTERIZATION BLACKOUT/DOME LIGHT WIRING HARNESS

REPLACEMENT
This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 Ž Battery ground cable disconnected (para. 4-73).
Ž Cargo floor cover removed (para. 12-110).
Tools Ž Blackout/dome light switch removed
automotive (Appendix B, Item 1) Ž Blackout/dome light door switch removed
(para. 12-107).
Manual References
TM 9-2320-280-10
TM 9-2320-280-24P
NOTE
a. Removal
1. Remove four screws (22) and upper side channel (23) from left end closure (24).
2. Remove ten screws (26) and lower side channel (25) from left end closure (24).
3. Remove four screws (19) and right blackout/dome light assembly (1) from right end closure (27).
4. Disconnect harness leads 712C (7) and 719C (6) from dome light leads 711/712 (8) and 719 (9).
5. Disconnect harness leads 711C (2) and 2C (3) from blackout light leads 711/712 (5) and 717 (4).
6. Remove four screws (21) and left blackout/dome light assembly (10) from left end closure (24).
7. Disconnect harness leads 712B (13) and 719B (14) from dome light leads 711/712 (12) and 719 (11).
8. Disconnect harness leads 711B (16) and 2B (15) from blackout light leads 711/712 (17) and 717 (18)
and remove wiring harness (20).
b. Installation
1. Connect harness leads 711B (16) and 2B (15) to blackout light leads 711/712 (17) and 717 (18).
2. Connect harness leads 712B (13) and 719B (14) to dome light leads 711/712 (12) and 719 (11).
3. Install left blackout/dome light assembly (10) on left end closure (24) with four screws (21).
4. Connect harness leads 711C (2) and 2C (3) to blackout light leads 711/712 (5) and 717 (4).
5. Connect harness leads 712C (7) and 719C (6) to dome light leads 711/712 (8) and 719 (9).
6. Install right blackout/dome light assembly (1) on right end closure (27) with four screws (19).
7. Install wiring harness (20) under lower side channel (25) and install lower side channel (25)
to left end closure (24) with ten screws (26).
8. Install wiring harness (20) under upper side channel (23) and install upper side channel (23)
to left end closure (24) with four screws (22).
12-154
TM 9-2320-280-20-3
12-105. TROOP/CARGO WINTERIZATION BLACKOUT/DOME LIGHT WIRING HARNESS

FOLLOW-ON TASKS: Ž Install blackout/dome light door switch (para. 12-107).

Ž Install blackout/dome light switch (para. 12-106).
Ž Install cargo floor cover (para. 12-110).
Ž Check blackout light and dome light for proper operation (TM 9-2320-280-10).
12-155
TM 9-2320-280-20-3
12-106. TROOP/CARGO WINTERIZATION BLACKOUT/DOME LIGHT SWITCH

REPLACEMENT
This task covers:
INITIAL SETUP:
Appliable Models Manual References
M998, M998A1, M1038, M1038A1 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
Equipment Condition
a. Removal
1. Remove nut (7) from box (3).

2. Remove two screws (2), box (3), and switch (9) from upper side channel (1) and lower side channel (4).
3. Inspect decal (8) and remove from box (3) if decal (8) is damaged or illegible.
NOTE
4. Remove three screws (5), washers (11), and leads 711A (6), 1B (12), and 712A (10)
from switch (9).
b. Installation
NOTE
Ensure lead 711A is positioned on top switch contact, and keyway
is on bottom of switch.
1. Install leads 711A (6), 1B (12), and 712A (10) on switch (9) with three washers (11) and screws (5).
Do not tighten screws (5).
2. Install decal (8) on box (3), if removed.
NOTE
Ensure keyway in switch is toward the "BLACKOUT" position
on box when installed.
3. Install switch (9) on box (3) with nut (7).
4. Tighten three screws (5) installed in step 1.
NOTE
Ensure electrical harness lead are not binding during box
installation.
5. Install box (3) on upper side channel (1) and lower side channel (4) with two screws (2).
12-156
TM 9-2320-280-20-3
12-106. TROOP/CARGO WINTERIZATION BLACKOUT/DOME LIGHT SWITCH


12-157
TM 9-2320-280-20-3
12-107. TROOP/CARGO WINTERIZATION BLACKOUT/DOME LIGHT DOOR SWITCH

REPLACEMENT
This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
Materials/Parts
a. Removal
1. Remove six screws (2) and top channel (1) from left end closure (3) and right end closure (4).
2. Remove four screws (7), locknuts (5), four clamps (6), and wiring harness (11) from top channel (1).
3. Remove two screws (12), nuts (8), washers (9), and switch (10) from top channel (1).
NOTE
4. Remove two screws (16), washers (15), and leads 719A (14) and 2D (13) from switch (10).
b. Installation
1. Install leads 719A (14) and 2D (13) on switch (10) with two washers (15) and screws (16).
2. Install switch (10) on top channel (1) with two screws (12), washers (9), and nuts (8).
3. Install four clamps (6) and wiring harness (11) on top channel (1) with four screws (7) and
locknuts (5).
4. Install top channel (1) on left end closure (3) and right end closure (4) with six screws (2).
12-158
TM 9-2320-280-20-3
12-107. TROOP/CARGO WINTERIZATION BLACKOUT/DOME LIGHT DOOR SWITCH


12-159
TM 9-2320-280-20-3
12-108. TROOP/CARGO WINTERIZATION BLACKOUT/DOME LIGHT ASSEMBLY

REPLACEMENT
This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
NOTE
Ž Replacement instructions for left and right blackout/dome
light assemblies are the same. This procedure covers right
blackout/dome light assembly.
a. Removal
1. Remove four screws (1) from blackout/dome light assembly (3) and right end closure (2).
2. Disconnect blackout light leads 717 (8) and 711/712 (9) from leads 2C (7) and 711C (6).
3. Disconnect dome light leads 719 (5) and 711/712 (4) from leads 719C (10) and 712C (11) and remove
blackout/dome light assembly (3).
b. Installation
1. Connect dome light leads 719 (5) and 711/712 (4) to leads 719C (10) and 712C (11).
2. Connect blackout light leads 717 (8) and 711/712 (9) to leads 2C (7) and 711C (6).
3. Install blackout/dome light assembly (3) on right end closure (2) with four screws (1).

12-160
TM 9-2320-280-20-3
12-109. TROOP/CARGO WINTERIZATION BLACKOUT/DOME LIGHT LAMP

REPLACEMENT
This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
a. Removal
NOTE
Perform steps 1 and 2 for blackout light lamp removal. Perform
steps 3 and 4 for dome light lamp removal.
1. Remove four screws (5) and blackout light cover and lens assembly (3) from light body (2).
2. Remove lamp (4) from light body (2).
3. Remove two screws (7) and dome light cover and lens assembly (6) from light body (1).
4. Remove lamp (8) from light body(1).
b. Installation
NOTE
Perform steps 1 and 2 for blackout light lamp installation. Perform
steps 3 and 4 for dome light lamp installation.
1. Install lamp (4) in light body (2).
2. Install blackout light cover and lens assembly (3) on light body (2) with four screws (5).
3. Install lamp (8) in light body (1).
4. Install dome light cover and lens assembly (6) on light body (1) with two screws (7).

12-161
TM 9-2320-280-20-3
12-110. TROOP/CARGO WINTERIZATION FRONT AND REAR CARGO FLOOR

COVER REPLACEMENT
This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-24P
General mechanic’s tool kit: Ž Heater base assembly removed (para. 12-98).
automotive (Appendix B, Item 1) Ž Heater wiring harness removed (para. 12-101).
Ž Circuit breaker removed (para. 12-103).
Materials/Parts Ž Skid strips removed (para. 12-111).
Four locknuts (Appendix G, Item 96) Ž Side wheelhousing covers removed
Six platenuts (Appendix G, Item 168) (para. 12-115).
Nine rivnuts (Appendix G, Item 202
a. Removal
1. Remove screw (1) and clamp (2) from blackout/dome light wiring harness (3) and front cargo
floor cover (4).
2. Remove two locknuts (11), washers (10), and screws (8) from door and frame assembly (9), rear cargo
floor cover (7), cargo floor (15), and "D" beam (14). Discard locknuts (11).
3. Remove two locknuts (12), washers (13), and capscrews (16) from door and frame assembly (9), rear
cargo floor cover (7), cargo floor (15), and "D" beam (14). Discard locknuts (12).
4. Remove two screws (5) and step latch strip (6) from rear cargo floor cover (7).
5. Remove nine screws (17), front cargo floor cover (4), and rear cargo floor cover (7) from cargo
floor (15).
6. Inspect nine rivnuts (18) for damage. Replace if damaged.
7. Inspect six platenuts (19) for damage. Replace if damaged.
b. Installation
NOTE
Ensure position markers on blackout/dome light wiring harness
extend beyond the front and rear cargo floor covers.
1. Install front cargo floor cover (4) and rear cargo floor cover (7) on cargo floor (15) with nine
screws (17).
2. Install step latch strip (6) on rear cargo floor cover (7) with two screws (5).
3. Install door and frame assembly (9) and rear cargo floor cover (7) on cargo floor (15) and
"D" beam (14) with two capscrews (16), washers (13), and locknuts (12).
4. Secure door and frame assembly (9) and rear cargo floor cover (7) to cargo floor (15) and
“D” beam (14) with two screws (8), washers (10), and locknuts (11).
5. Install blackout/dome light wiring harness (3) on front cargo floor (4) with clamp (2) and screw (1).
12-162
TM 9-2320-280-20-3
12-110. TROOP/CARGO WINTERIZATION FRONT AND REAR CARGO FLOOR COVER

FOLLOW-ON TASKS: Ž Install side wheelhousing covers (para. 12-115).

Ž Install skid strips (para. 12-111).
Ž Install circuit breaker (para. 12-103).
Ž Install heater wiring harness (para. 12-101).
Ž Install heater base assembly (para. 12-98).
12-163
TM 9-2320-280-20-3
12-111. TROOP/CARGO WINTERIZATION CARGO FLOOR SKID STRIPS

REPLACEMENT
This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-24P
General mechanic’s tool kit: Floor bracket removed (para. 12-99).
a. Removal
1. Remove fourteen screws (4) and two skid strips (3) from front cargo floor cover (1) and rear cargo
floor cover (6).
2. Remove five screws (2) and skid strip (5) from rear cargo floor cover (6).
b. Installation
1. Install skid strip (5) on rear cargo floor cover (6) with five screws (2).
2. Install two skid strips (3) to front cargo floor cover (1) and rear cargo floor cover (6) with fourteen
screws (4).
FOLLOW-ON TASK: Install floor bracket (para. 12-99).
12-164
TM 9-2320-280-20-3
12-112. TROOP/CARGO WINTERIZATION SEAT BACK COVER REPLACEMENT

This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 Four locknuts (Appendix G, Item 96)
NOTE
Replacement instructions for left and right seat back covers are
the same. This procedure covers right seat back cover.
a. Removal
1. Remove two turnscrews (1) and seat back (4) from body (7).
2. Remove four locknuts (6), washers (5), screws (2), and seat back cover (3) from seat back (4). Discard
locknuts (6).
b. Installation
1. Install seat back cover (3) on seat back (4) with four screws (2), washers (5), and locknuts (6).
2. Install seat back (4) on body (7) with two turnscrews (1).
12-165
TM 9-2320-280-20-3
12-113. TROOP/CARGO WINTERIZATION FIXED DOOR COVER REPLACEMENT

This task covers:
INITIAL SETUP:
M998, M989A1, M1038, M1038A1 Two locknuts (Appendix G, Item 95)
NOTE
Replacement instructions for left and right fixed door covers are
the same. This procedure covers right fixed door cover.
a. Removal
Remove two locknuts (3), washers (2), screws (4), and fixed door cover (1) from fixed door (5). Discard
locknuts (3).
b. Installation
Install fixed door cover (1) on fixed door (5) with two screws (4), washers (2), and locknuts (3).
12-166
TM 9-2320-280-20-3
12-114. TROOP/CARGO WINTERIZATION SIDE FLOOR COVER REPLACEMENT

This task covers:
INITIAL SETUP:
NOTE
Replacement instructions for left and right side floor covers are
the same. This procedure covers right side floor cover.
a. Removal
1. Remove two turnscrews (1) and seat back (2) from body (8).
2. Remove four locknuts (6), washers (7), screws (4), and side floor cover (3) from cargo floor (5).
b. Installation
1. Install side floor cover (3) on cargo floor (5) with four screws (4), washers (7), and locknuts (6).
2. Install seat back (2) on body (8) with two turnscrews (1).
12-167
TM 9-2320-280-20-3
12-115. TROOP/CARGO WINTERIZATION WHEELHOUSING COVERS REPLACEMENT

This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-24P
General mechanic’s tool kit: Troop seat removed (para. 12-121).
Materials/Parts
NOTE
Replacement instructions for left and right wheelhousing covers
are the same. This procedure covers right wheelhousing covers.
a. Removal
1. Remove four locknuts (2), washers (3), screws (5), and front cover (1) from wheelhousing (4). Discard
locknuts (2).
2. Remove twelve locknuts (7), washers (6), screws (9), and side cover (8) from wheelhousing (4).
3. Remove six locknuts (12), washers (13), screws (11), and top cover (10) from wheelhousing (4).
4. Remove six screws (14) and six spacers (15) from top cover (10).
b. Installation
1. Install six spacers (15) on top cover (10) with six screws (14).
2. Install top cover (10) on wheelhousing (4) with six screws (11), washers (13), and lockuts (12).
3. Install side cover (8) on wheelhousing (4) with twelve screws (9), washers (6), and locknuts (7).
4. Install front cover (1) on wheelhousing (4) with four screws (5), washers (3), and locknuts (2).
12-168
TM 9-2320-280-20-3
12-115. TROOP/CARGO WINTERIZATION WHEELHOUSING COVERS REPLACEMENT

(Cont’d)
FOLLOW-ON TASK: Install troop seat (para. 12-121).
12-169
TM 9-2320-280-20-3
12-116. TROOP/CARGO WINTERIZATION DOOR ADJUSTMENT

This task covers:
Adjustment
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 One mechanic
One assistant
Tools
TM 9-2320-280-24P
Materials/Parts
Adjustment
NOTE
Ž Adjustment of door and frame assembly may be required if
door is not centered or binds during opening or closing.
Ž Ensure door has an equal distance around frame assembly
in both vertical and horizontal directions.
Ž For vertical or horizontal door adjustment, perform step 1.
Ž For lateral door adjustment, perform steps 2 and 3.
Ž For dome light on/off adjustment, perform steps 4 through 10.
1. Loosen eight nuts (14) and capscrews (11) from two hinges (2) and frame assembly (3) and lift
or lower door (1) as required. Tighten nuts (14) to 85-90 lb-ft (115-122 NŽm).
2. Remove eight locknuts (13) from door (1) and two hinges (2). Discard locknuts (13).
3. Add or remove shims (12) from door (1), as required. Install and tighten locknuts (13) to 50-55 lb-ft
(68-75 NŽm).
4. Place dome light switch in "DOME LIGHT" position (TM 9-2320-280-10).
5. With door (1) in open position loosen upper jamnut (6) and lower jamnut (7) to maximum outward
position on control rod (8).
6. Close and fasten door (1).
7. Align rod (10) of actuator light control (9) with center of control arm (5) on door switch assembly (4).
8. Engage control arm (5) by adjusting lower jamnut (7) upward on control arm (5) and actuator light
control (9) until dome lights are on.
9. Adjust lower jamnut (7) 0.25 in. (6.4 mm) beyond initial adjustment made in step 8.
10. Adjust upper jamnut (6) on control rod (8) down on actuator light control (9) and tighten jamnut (6).
12-170
TM 9-2320-280-20-3
12-116. TROOP/CARGO WINTERIZATION DOOR ADJUSTMENT (Cont’d)
12-171
TM 9-2320-280-20-3
12-117. TROOP/CARGO WINTERIZATION DOOR AND FRAME ASSEMBLY

REPLACEMENT
This task covers:
INITIAL SETUP:
One assistant
Tools
Manual References
Two locknuts (Appendix G, Item 66) Ž End closures removed (para. 12-118).
Ten locknuts (Appendix G, Item 95) Ž Rear step assembly removed (para. 12-122).
Twelve locknuts (Appendix G, Item 97)
a. Removal
1. Shut door (1) and close latch (2).

2. Remove eight nuts (6) capscrews (5), and shims (if installed) from two hinges (3) and frame
assembly (4).
3. Open latch (2) and remove door (1) and two hinges (3) from frame assembly (4).
4. Remove two locknuts (17) and screws (15) from channel (9) and top enclosure plate support (16).
5. Remove eight locknuts (21), screws (19), and washers (18) from channel (9) and top enclosure
6. Remove two locknuts (26), washers (27), and capscrews (22) from frame assembly (4), rear
floor cover (30), cargo floor (29), and "D" beam (28). Discard locknuts (26).
7. Remove two locknuts (25), washers (24), and screws (23) from frame assembly (4), rear floor
cover (30), cargo floor (29), and "D" beam (28). Discard locknuts (25).
8. Remove four locknuts (11), washers (12), capscrews (14), washers (13), and frame assembly (4) from
support (10). Discard locknuts (11).
9. Remove two locknuts (35) and capscrews (34) from trailer mount bracket (36) and support (10).
10. Remove four locknuts (31), washers (32), capscrews (33), and support (10) from “D” beam (28).
11. Remove four locknuts (8), capscrews (7), and frame assembly (4) from channel (9). Discard locknuts (8).
12-172
TM 9-2320-280-20-3

12-173
TM 9-2320-280-20-3

b. Installation
1. Install support (4) on "D" beam (5) with four capscrews (3), washers (2), and locknuts (1).
2. Install trailer mount bracket (8) on support (4) with two capscrews (6) and locknuts (7).
3. Install frame assembly (11) on channel (20) with four capscrews (18) and locknuts (19).
4. Install frame assembly (11) and channel (20) on support (4) with four washers (23), capscrews (24),
5. Install frame assembly (11) on rear floor cover (17), cargo floor (16), and "D" beam (5) with two
6. Secure frame assembly (11) to rear floor cover (17), cargo floor (16), and “D” beam (5) with two
7. Install channel (20) on top enclosure assembly (30) with eight washers (28), screws (29), and
locknuts (31).
8. Install channel (20) on top enclosure plate support (26) with two screws (25) and locknuts (27).
NOTE
Ensure shims are added as required.
9. Install door (32) and two hinges (33) on frame assembly (11) with eight capscrews (34) and nuts (35).
Tighten nuts (35) to 85-90 lb-ft (115-122 NŽm).
12-174
TM 9-2320-280-20-3

FOLLOW-ON TASKS: Ž Install rear step assembly (para. 12-122).

Ž Install end closures (para. 12-118).
Ž Adjust door (para. 12-116).
12-175
TM 9-2320-280-20-3
12-118. TROOP/CARGO WINTERIZATION END CLOSURE REPLACEMENT

This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-24P
General mechanic’s tool kit: Ž Rear reflector removed (para. 12-126).
automotive (Appendix B, Item 1) Ž Rear composite light housing removed para. 12-127).
Ž Handle assembly removed (right end closure
Materials/Parts only) (para. 12-123).
Twelve locknuts (Appendix G, Item 97) Ž Antenna mounting bracket removed (right end
closure only) (para. 12-125).
Personnel Required Ž Fuel can mounting bracket removed (left end
One mechanic closure only) (para. 12-124).
One assistant Ž Blackout/dome light wiring harness removed
(para. 12-105).
a. Removal
NOTE
Replacement instructions for left and right end closures are
basically the same. This procedure covers right end closure.
1. Remove seven screws (1) and clamping strip (9) from top cover assembly (5), channel (10), and right
end closure (6).
2. Remove three screws (2) and clamping strip (3) from top cover assembly (5), outside corner plate (4),
and right end closure (6).
3. Remove eight screws (8) and clamping strip (7) from top cover assembly (5), and right end closure (6).
4. Remove screw (14) from clamping strip (15), top cover assembly (5) and right end closure (6).
5. Remove eight nuts (11), capscrews (13), clamping strip (15), and top cover assembly (5) from right
rear vehicle body (12).
12-176
TM 9-2320-280-20-3
12-118. TROOP/CARGO WINTERIZATION END CLOSURE REPLACEMENT (Cont’d)

6. Remove three locknuts (27), screws (26), and outside corner plate (4) from inside corner
bracket (28), and right end closure (6). Discard locknuts (27).
7. Remove locknut (18) and screw (17) from right end closure (6) and channel (10). Discard
locknut (18).
8. Remove two locknuts (19) and capscrews (16) from right end closure (6) and channel (10). Discard
locknuts (19).
9. Remove four locknuts (21) and capscrews (25) from right end closure (6) and door and frame
10. Remove two locknuts (23), capscrews (24), and right end closure (6) from support assembly (22).
12-177
TM 9-2320-280-20-3

b. Installation
NOTE
Ensure lower right corner of end closure is flush with support assembly.
1. Position right end closure (9) on support assembly (10), door and frame assembly (7), and
channel (1).
2. Secure right end closure (9) to support assembly (10) with two capscrews (12) and locknuts (11).
3. Install right end closure (9) on door and frame assembly (7) with four capscrews (13) and
locknuts (8).
4. Install right end closure (9) on channel (1) with two capscrews (2) and locknuts (5).
5. Secure right end closure (9) to channel (1) with screw (3) and locknut (4).
6. Install outside corner plate (14) on right end closure (9) and inside corner bracket (16) with three
screws (17) and locknuts (15).
12-178
TM 9-2320-280-20-3

7. Install top cover assembly (6) on right rear vehicle body (19) with strip (22), eight capscrews (20),
and nuts (18).
8. Install top cover assembly (6) on right end closure (9) with strip (22) and screw (21).
9. Secure top cover assembly (6) to right end closure (9) with strip (26) and eight screws (27).
10. Install top cover assembly (6) on outside corner plate (14) and right end closure (9) with strip (25)
and three screws (24).
11. Install top cover assembly (6) on channel (1) and right end closure (9) with strip (28) and seven
screws (23).
FOLLOW-ON TASKS: Ž Install blackout/dome light wiring harness (para. 12-105).

Ž Install fuel can mounting bracket (left end closure only) (para. 12-124).
Ž Install antenna mounting bracket (right end closure only) (para. 12-125).
Ž Install handle assembly (right end closure only) (para. 12-123).
Ž Install rear composite light housing (para. 12-127).
Ž Install rear reflector (para. 12-126).
12-179
TM 9-2320-280-20-3
12-119. TROOP/CARGO WINTERIZATION TOP COVER ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
One assistant
Tools
Adhesive spray (Appendix C, Item 8) Air intake assembly removed (para. 12-97).
Two seals (Appendix G, Item 220)
a. Removal
1. Remove nut (2) and capscrew (1), from clamping strip (16), top cover assembly (5), seal (13), and left
rear fixed door (12).
2. Remove six nuts (14), capscrews (15), and clamping strip (16) from top cover assembly (5), seal (13),
and left rear fixed door (12).
3. Remove screw (9) from clamping strip (11), top cover assembly (5), seal (13), and left end closure (7).
4. Remove ten nuts (6), capscrews (10), and clamping strip (11) from top cover assembly (5), seal (13),
and left rear vehicle body (8).
5. Remove and discard seal (13).
6. Remove nut (19) and capscrew (22) from clamping strip (23), top cover assembly (5), seal (35), and
right rear fixed door (24).
7. Remove six nuts (18), capscrews (25), and clamping strip (23) from top cover assembly (5), seal (35),
and right rear fixed door (24).
8. Remove three screws (26), spring nuts (17), (if damaged) and plate assembly (27) from top cover
assembly (5), seal (35), fuel tank filler (28), and right rear vehicle body (32).
9. Remove screw (31) from clamping strip (29), top cover assembly (5), seal (35), and right end
closure (33).
10. Remove eight nuts (34), capscrews (30), clamping strip (29), top cover assembly (5), and seal (35)
from right rear vehicle body (32). Discard seal (35).
11. Remove sixteen screws (47), two clamping strips (46), and two seals (44) from rear end closure
assembly (45) and top cover (5). Discard seals (44).
12. Remove six screws (36), two clamping strips (37), seals (43), and outside corner plates (42) from rear end
closure assembly (45) and top cover (5). Discard seals (43).
13. Remove fourteen screws (39), two clamping strips (38), and seals (41) from channel (40), top
cover (5), and two rear end closure assemblies (45). Discard seals (41).
14. Detach eight fastener straps 3 from bow assemblies (4).
15. Detach top cover assembly fastener strip (21) from cab top cover strip (20).
16. Remove top cover assembly (5).
12-180
TM 9-2320-280-20-3

(Cont’d)
12-181
TM 9-2320-280-20-3
12-119. TROOP/CARGO WINTERIZATION TOP COVER ASSEMBLY REPLACEMENT (Cont'd)
b. Installation
1. Apply adhesive spray to channel (3) and mating surfaces of two seals (2) and install seals (2) on
channel (3).
2. Apply adhesive spray to outside corner plates (4) and mating surfaces of two seals (1) and install
seals (1) on outside corner plates (4).
3. Apply adhesive spray to two rear end closure assemblies (6) and mating surfaces of seals (5) and
install seals (5) on rear end closure assembly (6).
4. Apply adhesive spray to right side of vehicle (8) and mating surface of seal (7) and install seal (7) on
right side of vehicle (8).
5. Apply adhesive spray to left side of vehicle (10) and mating sufrace of seal (9) and install seal (9) on
left side of vehicle (10).
6. Apply an even coat of sealant to two top enclosure assemblies (13), rear end closure assemblies (17),
corner edges (19), and other shaded areas.
7. Apply sealant to top enclosure assembly clamps (11), plates (14), and screws (12).
NOTE
If raised edges or gaps exist around areas of outside corner plates
and rear end closure assembly, fill with sealant.
8. Apply sealant to outside corner plates (15) and channel assembly (16).
9. Apply sealant to any open gaps on rear end closure assembly (17) and vehicle body (18).
12-182
TM 9-2320-280-20-3

(Cont’d)
12-183
TM 9-2320-280-20-3

(Cont’d)
NOTE
When installing top cover assembly, ensure fastener straps are
installed on inside of enclosure.
10. Center and install top cover assembly (6) over top enclosure assembly (7), rear end closure
assemblies (13), and vehicle body (12).
11. Attach top cover assembly fastener strip (20) to cab top cover strip (19).
12. Install eight fastener straps (37) on bow assemblies (38).
NOTE
Top cover assembly is oversized to allow for shrinkage for proper fit.
13. Install top cover assembly (6) and two clamping strips (3) on two seals (8), channel (5), and rear end
closure assemblies (13) with fourteen screws (4).
14. Install top cover assembly (6) and two clamping strips (2) on two seals (10), outside corner plates (9),
and rear end closure assemblies (13) with six screws (1).
15. Install top cover assembly (6) and two clamping strips (14) on two seals (11) and rear end closure
assemblies (13) with sixteen screws (15).
16. Install top cover assembly (6) and clamping strip (28) on seal (34) and right rear vehicle body (31)
with eight capscrews (29) and nuts (33).
17. Secure top cover assembly (6) and clamping strip (28) to seal (34) and right end closure (32) with
screw (30).
18. Install top cover assembly (6) and plate assembly (26) on seal (34), fuel tank filler (27), and right
rear vehicle body (31) with three screws (25) and spring nuts (16) (if removed).
19. Install top cover assembly (6) and clamping strip (22) on seal (34) and right rear fixed door (23) with
six capscrews (24) and nuts (17).
20. Secure top cover assembly (6) and clamping strip (22) to seal (34) and right rear fixed door (23) with
capscrew (21) and nut (18).
21. Install top cover assembly (6) and clamping strip (44) on seal (46) and left rear vehicle body (41) with
ten capscrews (43) and nuts (39).
22. Install top cover assembly (6) and clamping strip (44) on seal (46) and left end closure (40) with
screw (42).
23. Install top cover assembly (6) and clamping strip (49) on seal (46) and left rear fixed door (45) with
six capscrews (48) and nuts (47).
24. Secure top cover assembly (6) and clamping strip (49) to seal (46) and left rear fixed door (45) with
capscrew (35) and nut (36).
12-184
TM 9-2320-280-20-3
12-119. TROOP/CARGO WINTERIZATION TOP COVER ASSEMBLY REPLACEMENT (Cont'd)
12-185
TM 9-2320-280-20-3
12-120. TROOP/CARGO WINTERIZATION TOP ENCLOSURE ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
One assistant
Tools
Adhesive (Appendix C, Item 7) Top cover assembly removed (para. 12-119).
Eighteen locknuts (Appendix G, Item 95)
a. Removal
1. Remove safety caps (2) as required from top enclosure assembly mounting screws (1).
2. Remove six locknuts (9) and screws (5), and two outside plates (4) from inside corner brackets (6),
and end enclosures (8). Discard locknuts (9).
NOTE
For installation, note size and location of inside corner bracket
mounting screws.
3. Remove four locknuts (7) and screws (11) from two inside corner brackets (6) and supports (3).
4. Remove four locknuts (10) and screws (12) from two inside corner brackets (6) and supports (3).
5. Remove two locknuts (17) and screws (15) from plate (14), channel (13), and two supports (16).
6. Remove eight locknuts (20), screws (19), and washers (18) from two supports (3) and channel (13).
7. Remove sixteen nuts (38), screws (40), and eight clamps (39) from two supports (21), supports (3),
rear bow (24), and middle bow (23).
8. Remove four nuts (35), screws (37), clamps (36), two supports (21), and supports (3) from front
bow (22).
9. Remove sixteen nuts (31), screws (28), eight support plates (29), and clamps (30) from two supports (16),
rear bow (24), and middle bow (23).
10. Remove six nuts (34), screws (32), and clamps (33) from two supports (16), plate (14), and
front bow (22).
11. Remove eight nuts (27), screws (25), four clamps (26), two supports (16), and plate (14) from rear
bow (24) and middle bow (23).
12-186
TM 9-2320-280-20-3

(Cont’d)
12-187
TM 9-2320-280-20-3

(Cont’d)
b. Installation
1. Install plate (2) and two supports (3) on front bow (5), middle bow (6), and rear bow (7) with four
clamps (9), eight screws (8) and nuts (10).
2. Secure plate (2) and two supports (3) to front bow (5) with six clamps (16), screws (15), and nuts (17).
3. Install two supports (3) on rear bow (7) and middle bow (6) with eight clamps (13), support
plates (12), sixteen screws (11), and nuts (14).
4. Install two supports (4) and supports (1) on front bow (5), middle bow (6), and rear bow (7) with four
clamps (19), screws (20), and nuts (18).
5. Install two supports (4) and supports (1) on rear bow (7) and middle bow (6) with eight clamps (22),
sixteen screws (23), and nuts (21).
6. Install two supports (1) on channel (33) with eight washers (36), screws (37), and locknuts (38).
7. Install plate (2) on channel (33) and two supports (16) with two screws (34) and locknuts (35).
8. Install two outside plates (24) and inside corner brackets (26) on two end closures (28) with six
9. Install two inside corner brackets (26) on two supports (1) with four screws (32) and locknuts (30).
10. Secure two inside corner brackets (26) to two supports (1) with four screws (31) and locknuts (27).
11. Apply adhesive to exposed threads of top enclosure assembly mounting screws (39) and install safety
caps (40) on screws (39) as required.
12-188
TM 9-2320-280-20-3

(Cont’d)
FOLLOW-ON TASK: Install top cover assembly (para. 12-119).
12-189
TM 9-2320-280-20-3
12-121. TROOP/CARGO WINTERIZATION TROOP SEAT ASSEMBLY AND BOW

REPLACEMENT
This task covers:
INITIAL SETUP:
One assistant
Tools
Nine locknuts (Appendix G, Item 98) Top enclosure assembly removed (para. 12-120).
NOTE
Replacement instructions for left and right troop seat assemblies
are the same. This procedure covers left troop seat assembly.
a. Removal
1. Remove plate (1) from front bow (20).

2. Remove front bow (20), middle bow (2), and rear bow (3) from troop seat assembly (9).
3. Remove six locknuts (11), washers (10), capscrews (13), and washers (12) from troop seat
assembly (9) and wheelhousing (14). Discard locknuts (11).
4. Remove three locknuts (25), washers (26), capscrews (28), and washers (27) from rear corner troop
seat bracket (29) and wheelhousing (14). Discard locknuts (25).
5. Remove two locknuts (24), washers (23), and capscrews (21) from front wheelhousing bracket (22) and
wheelhousing (14). Discard locknuts (24).
6. Remove troop seat assembly (9) from wheelhousing (14) and support assembly (16).
7. Remove three locknuts (19), washers (18), and capscrews (15) from support assembly (16) and
"B" pillar (17). Discard locknuts (19).
8. Remove two locknuts (8), washers (7), screws (5), and block (6) from cargo bulkhead (4).
12-190
TM 9-2320-280-20-3

12-191
TM 9-2320-280-20-3

b. Installation
1. Install block (6) on cargo bulkhead (4) with two screws (5), washers (7), and locknuts (8).
NOTE
Support assembly must be installed with narrow offset to outside
of vehicle and rounded side up.
2. Install support assembly (16) on “B” pillar (17) with three capscrews (15), washers (18), and
locknuts (19).
3. Install troop seat assembly (9), folded in stowed position, into support assembly (16) and on
wheelhousing (14).
4. Install front wheelhousing bracket (22) on wheelhousing (14) with two capscrews (21), washers (23),
and locknuts (24). Tighten locknuts (24) to 49 lb-ft (66 NŽm).
5. Install rear corner troop seat bracket (29) on wheelhousing (14) with three washers (27),
capscrews (28), washers (26), and locknuts (25). Tighten locknuts (25) to 96 lb-in. (11 NŽm).
6. Install troop seat assembly (9) on wheelhousing (14) with six washers (12), capscrews (13),
washers (10), and locknuts (11). Tighten locknuts (11) to 96 lb-in. (11 NŽm).
7. Install front bow (20), middle bow (2), and rear bow (3) on slots on outside of troop seat
assembly (9).
8. Install plate (1) on front bow (20).
12-192
TM 9-2320-280-20-3

FOLLOW-ON TASK: Install top enclosure assembly (para. 12-120).
12-193
TM 9-2320-280-20-3
12-122, TROOP/CARGO WINTERIZATION REAR STEP ASSEMBLY REPLACEMENT

This task covers:
lNITIAL SETUP:
M998, M998A1, M1038, M1038A1 Two cotter pins (Appendix G, Item 17)
a. Removal
1. Remove two cotter pins (7), clevis pins (6), and step assembly (5) from door and frame assembly (4).
2. Remove two screws (1) and step latch strip (2) from cargo floor cover (3).
b. Installation
1. Install step latch strip (2) on cargo floor cover (3) with two screws (1).
2. Install step assembly (5) on door and frame assembly (4) with two clevis pins (6) and cotter pins (7).
12-194
TM 9-2320-280-20-3
12-123. TROOP/CARGO WINTERIZATION HANDLE ASSEMBLY REPLACEMENT

This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 Adhesive (Appendix C, Item 7)
Tools
a. Removal
Remove two safety caps (4), locknuts (3), washers (2), handle assembly (6) and two
washers (1) from right end closure (5). Discard locknuts (3).
b. Installation
1. Install two washers (1) and handle assembly (6) on right end closure (5) with two washers (2) and
locknuts (3).
2. Apply adhesive to exposed threads of handle assembly (6) and install two safety caps (4) on handle
assembly (6).
12-195
TM 9-2320-280-20-3
12-124. TROOP/CARGO WINTERIZATION FUEL CAN MOUNTING BRACKET REPLACEMENT

This task covers:
INITIAL SETUP:
a. Removal
1. Remove two locknuts (1), plate (2), and two capscrews (4) from fuel can mounting bracket (5) and left
end closure (7). Discard locknuts (1).
2. Remove two locknuts (10), washers (9), capscrews (6), and fuel can mounting bracket (5) from left
end closure (7). Discard locknuts (10).
3. Remove two spacers (8) from lower mounting holes (3) in left end closure (7).
1. Install two spacers (8) in lower mounting holes (3) in left end closure (7).
2. Install fuel can mounting bracket (5) on left end closure (7) with two capscrews (6), washers (9), and
locknuts (10).
3. Secure fuel can mounting bracket (5) and plate (2) to left end closure (7) with two capscrews (4) and
locknuts (1).
4. Tighten two locknuts (1) and locknuts (10) to 34 lb-ft (46 NŽm).
12-196
TM 9-2320-280-20-3
12-125. TROOP/CARGO WINTERIZATION ANTENNA MOUNTING BRACKET REPLACEMENT

This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-24P
General mechanic’s tool kit: Ž AS 1729/VRC antenna removed
automotive (Appendix B, Item 1) (para. 12-137), if installed.
Ž AB-652/GR antenna removed (para. 12-139),
Materials/Parts if installed.
a. Removal
1. Remove three locknuts (4), washers (3), capscrews (8), washers (6), and antenna mounting
bracket (2) from right end closure (7). Discard locknuts (4).
2. Remove three spacers (5) from right end closure (7).
3. Remove grommet (1) from antenna mounting bracket (2).
b. Installation
1. Install grommet (1) on antenna mounting bracket (2).

2. Install three spacers (5) on right end closure (7).
3. Install antenna mounting bracket (2) on right end closure (7) with three washers (6), capscrews (8),
washers (3), and locknuts (4). Tighten locknuts (4) to 15 lb-ft (20 NŽm).
FOLLOW-ON TASKS: Ž Install AS 1729/VRC antenna (para. 12-137), if removed.

Ž Install AB-652/GR antenna (para. 12-139), if removed.
12-197
TM 9-2320-280-20-3
12-126. TROOP/CARGO WINTERIZATION REAR REFLECTOR REPLACEMENT

This task covers:
lNITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-24P
Tools
NOTE
Replacement instructions for left and right rear reflectors are the
same. This procedure covers right rear reflector.
a. Removal
Remove two screws (3) and reflector (2) from right end closure (1).
b. Installation
Install reflector (2) on right end closure (1) with two screws (3).
12-198
TM 9-2320-280-20-3
12-127. TROOP/CARGO WINTERIZATION REAR COMPOSITE LIGHT HOUSING REPLACEMENT

This task covers:
lNITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-24P
General mechanic’s tool kit: Rear composite light assembly removed
NOTE
Replacement instructions for left and right rear composite light
housings are the same. This procedure covers right rear composite
light housing.
a. Removal
Remove eight screws (3) and rear composite light housing (1) from right end closure (2).
b. Installation
Install rear composite light housing (1) on right end closure (2) with eight screws (3).
FOLLOW-ON TASK: Install rear composite light housing (para. 4-56).
12-199
TM 9-2320-280-20-3
12-128. TROOP/CARGO WINTERIZATION DATA PLATE REPLACEMENT

This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-24P
Tools
a. Removal
Remove four screws (3) and data plate (1) from left end closure (2).
b. Installation
Install data plate (1) on left end closure (2) with four screws (3).
12-200
TM 9-2320-280-20-3
Section VII. COMMUNICATIONS KITS MAINTENANCE
1 2 - 1 2 9 . C O M M U N I C ATIONS KITS MAINTENANCE TASK SUMMARY
TASK PAGE
PROCEDURES
PARA. NO.
12-130. Front Radio Rack Mounting Bracket Replacement 12-202

12-131. Auxiliary Shelf Replacement 12-202.1
12-131.1. Front Radio Rack Upper Mounting Brackets Replacement 12-202.2
12-132. Front Radio Rack Replacement 12-204
12-132.1. Installation of New Configuration Front Radio Rack Bracket 12-204.2
12-133. Front Lower Radio Rack Replacement 12-206
12-134. Dual TSEC/KY-57 Mounting Bracket and 12-207
Control Switch Bracket Replacement
12-135. Speaker Stop Replacement 12-208
12-136. Antenna Ground Strap Replacement 12-209
12-137. AS 1729/VRC Antenna Replacement 12-211
12-138. Rear Antenna Mounting Bracket Replacement 12-212
12-139. AB-652/GR Antenna Replacement 12-213
12-140. Rear Antenna Cables Replacement 12-214
12-141. Front Radio Rack Power Cable Replacement 12-221
12-142. Headphone Mounting Bracket Replacement 12-223
12-143. Handset Bracket Replacement 12-224
12-144. Rear Radio Rack Maintenance 12-225
12-145. Rear Radio Rack Antenna Tower Maintenance 12-228
12-146. Rear Radio Rack to Tower Antenna Cables 12-230
Replacement
12-147. Rear Radio Rack Power Cable Replacement 12-232
Change 1 12-201
TM 9-2320-280-20-3
1 2 - 1 3 0 . FRONT RADIO RACK MOUNTING BRACKET REPLACEMENT
This task covers:

INITIAL SETUP:
M997A1, M997A2, M1037, M1042, M1097, One assistant
M1097A1, M1097A2, M1123
Manual References
Tools TM 9-2320-280-24P
Radio rack assembly removed (para. 12-132).
a. Removal
NOT E
Brace is attached under the floor and secured by four capscrews
holding the two radio rack mounting brackets to the cargo floor.
1. Remove two capscrews (2), washers (1), and radio rack mounting bracket (3) from cargo floor (4).
NOT E
Perform step 2 for vehicles with new configuration.
2. Remove two capscrews (7), washers (6), and radio rack mounting bracket (5) from cargo floor (4).
b. Installation
1. Install radio rack mounting bracket (3) on cargo floor (4) with two washers (1) and capscrews (2).
Tighten capscrews (2) to 96 lb-in. (11 N•m).
NOT E
Perform step 2 for vehicles with new configuration.
2. Install radio rack mounting bracket (5) on cargo floor (4) with two washers (6) and capscrews (7).
Tighten capscrews (7) to 96 lb-in. (11 N•m).
NEW CONFIGURATION
FOLLOW-ON TASK: Install radio rack assembly (para. 12-132).
12-202 Change 1
TM 9-2320-280-20-3
1 2 - 1 3 1 . A U X I L I A RY SHELF REPLACEMENT
This task covers:

INITIAL SETUP:
Equipment Condition
Speaker stop removed (para. 12-135).
a. Removal
1. Remove two locknuts (7), washers (8), screws (2), from auxiliary shelf (6) and radio rack (1). Discard
locknuts (7).
2. Remove two locknuts (5), washers (4), capscrews (3), and auxiliary shelf (6) from radio rack (1).
b. Installation
1. Install auxiliary shelf (6) on radio rack (1) with two capscrews (3), washers (4), and locknuts (5).
2. Install radio rack (1) on auxiliary shelf (6) with two screws (2), washers (8), and locknuts (7).
FOLLOW-ON TASK: Install speaker stop (para. 12-135).
Change 1 12-202.1
TM 9-2320-280-20-3
1 2 - 1 3 1 . 1 . FRONT RADIO RACK UPPER MOUNTING BRACKETS REPLACEMENT
This task covers:

INITIAL SETUP:
M966, M998, M1025, M1026, M1036, M1038, TM 9-2320-280-24P
M1043, M1044, M1045, M1046, M1121
Equipment Condition
Tools Radio rack assembly removed (para. 12-132).
Personnel Required
One mechanic
One assistant
a. Removal
1. Remove two capscrews (4), washers (5), and radio rack mounting brackets (6) from plenum (7).
2. Remove nine screws (9), retainer (8), and plenum (7) from “A” beam (10).
3. Remove four capscrews (3), washers (2), and two radio rack upper mounting brackets (1) from
“A” beam (10).
b. Installation
1. Install two radio rack upper mounting brackets (1) on “A” beam (10) with four washers (2) and
capscrews (3).
2. Install retainer (8) and plenum (7) on “A” beam (10) with nine screws (9).
3. Install two radio rack mounting brackets (6) on plenum (7) with two washers (5) and capscrews (4).
12-202.2 Change 1
TM 9-2320-280-20-3
12-131.1. FRONT RADIO RACK UPPER MOUNTING BRACKETS REPLACEMENT (C

ont’d)
FOLLOW-ON TASK: Install radio rack assembly (para. 12-132).
Change 1 12-203
TM 9-2320-280-20-3
1 2 - 1 3 2 . FRONT RADIO RACK REPLACEMENT
This task covers:

INITIAL SETUP:
M997A1, M997A2, M1037, M1042, M1097,
M1097A1, M1097A2, M1123 Equipment Condition
• Headphone mounting bracket removed
Tools (para. 12-142).
General mechanic’s tool kit: • Dual TSEC/KY-57 mounting bracket and control
automotive (Appendix B, Item 1) switch bracket removed (para. 12-134) if installed.
• Auxiliary shelf removed (para. 12-131) if installed.
Materials/Parts
M966, M966A1, M1036, M1045, M1045A1,
Antiseize compound (Appendix C, Item 13) M1045A2, M1046, M1046A1, M1121 only:
Six locknuts (Appendix G, Item 106) • Vehicle power conditioner (VPC) mounting
Two nut and lockwasher assemblies bracket removed (para. 11-66).
(Appendix G, Item 146) • Field glasses bracket removed (para. 11-69).
a. Removal
1. Remove two nut and lockwasher assemblies (8), screws (5), two clamps (6), and cables (7) from radio
rack (4). Discard nut and lockwasher assemblies (8).
2. Remove two capscrews (1) and washers (2) from radio rack (4) and “A” beam (3).
NOT E
Perform steps 2.1 and 2.2 for vehicles with new configuration.
2.1. Remove two locknuts (15) and washers (14) from radio rack (4) and two radio rack upper
brackets (13). Discard locknuts (15).
2.2. Remove two locknuts (18), washers (17), capscrews (16), and radio rack (4) from two radio rack
mounting brackets (19) and remove radio rack (4). Discard locknuts (18).
3. Remove two locknuts (12), washers (11), capscrews (9), and radio rack (4) from radio rack mounting
b. Installation
1. Install radio rack (4) on radio rack mounting brackets (10) with two capscrews (9), washers (11), and
locknuts (12). Tighten locknuts (12) to 8-10 lb-ft (11-14 N•m).
NOT E
Perform steps 1.1 and 1.2 for vehicles with new configuration.
1.1. Install radio rack (4) on two radio rack mounting brackets (19) with capscrews (16), washers (17),
and locknuts (18). Tighten locknuts (18) to 8-10 lb-ft (11-14 N•m).
1.2. Install radio rack (4) on two radio rack upper brackets (13) with washers (14) and locknuts (15).
Tighten locknuts (15) to 8-10 lb-ft (11-14 N•m).
2. Install radio rack (4) on “A” beam (3) with two washers (2) and capscrews (1). Tighten capscrews (1)
to 6 lb-ft (8 N•m).
3. Install cables (7) and two clamps (6) on radio rack (4) with two screws (5) and nut and lockwasher
assemblies (8).
12-204 Change 1
TM 9-2320-280-20-3
1 2 - 1 3 2 . FRONT RADIO RACK REPLACEMENT( C o n t ’ d )
FOLLOW-ON TASKS: • Install headphone mounting bracket (para. 12-142).

• Install dual TSEC/KY-57 mounting bracket and control switch bracket,
(para. 12-134) if removed.
• Install auxiliary shelf (para. 12-131) if removed.
M966, M966A1, M1036, M1045, M1045A1, M1045A2, M1046, M1046A1, and
M1121 only.
• Install vehicle power conditioner (VPC) mounting bracket (para. 11-66).
• Install field glasses bracket (para. 11-69).
Change 1 12-204.1
TM 9-2320-280-20-3
1 2 - 1 3 2 . 1 . INSTALLATION OF NEW CONFIGURATION FRONT RADIO RACK BRACKET
This task covers:

a. Vehicle Preparation b. Installation
INITIAL SETUP:
M997A1, M997A2, M1037, M1042, M1097,
M1097A1, M1097A2, M1123 Equipment Condition
• Front radio rack removed (para. 12-132).
Tools • Front floorboard removed (para. 11-154).
General mechanic’s tool kit: • Front radio rack mounting bracket removed
• Engine access cover removed (para. 10-15).
Materials/Parts
Two locknuts (Appendix G, Item 94.1)
Two rivets (Appendix G, Item 177.1)
Sealant (Appendix C, Item 38)
a. Vehicle Preparation
NOTE
1. Remove nine screws (7), plenum panel (11), and engine shroud mount (6) from “A” beam (1).
2. Remove four nuts (5), washers (4), screws (2), and two mounting brackets (3) from “A” beam (1).
3. Remove two rivets (10) and radio rack brace (8) from tunnel floor (9).
12-204.2 Change 1
TM 9-2320-280-20-3
12-132.1. INSTALLATION OF NEW CONFIGURATION FRONT RADIO RACK BRACKET (Cont’d)
b. Installation
1. Locate, mark, and drill two 0.440-in. (11.18 mm) diameter holes (12) in plenum panel (11).
2. Locate, mark, and drill four 0.281-in. (7.1 mm) diameter holes (13) in “A” beam (1).
3. Cut two 0.75-in. (2 mm) square holes (15) in floor mat (14) on top of tunnel floor (9).
4. Using two radio rack mounting brackets (17) as a template, locate, mark, and drill two 0.313-in.
(8 mm) diameter holes (16) in top of tunnel floor (9).
5. Apply sealant to two holes (12) and two existing holes on plenum panel (11) and four holes (13) on
“A” beam (1).
1.250 in.
(31.75 mm)
EXISTING HOLES
Change 1 12-204.3
TM 9-2320-280-20-3
6. Position radio rack brace (13) under tunnel floor (15) and two radio rack mounting brackets (12) on
tunnel floor (15).
7. Install radio rack brace (13) and two radio rack mounting brackets (12) on tunnel floor (15) with four
screws (17) and washers (16).
8. Install plenum panel (1) and engine shroud mount (11) on “A” beam (5) with nine screws (10).
9. Using two holes (14) in tunnel floor (15) as a template, drill two 0.172-inch (4.3 mm) diameter holes
through radio rack brace (13).
NOTE
10. Install two rivets (27) in tunnel floor (15) and radio rack brace (13).
11. Install front floorboard (para. 11-154).
12. Install engine access cover (para. 10-15).
13. Install two radio mounting brackets (7) on “A” beam (5) with four screws (6), washers (8), and
locknuts (9).
14. Install two upper radio rack brackets (2) on plenum panel (1) with two screws (3) and washers (4).
15. Install front radio rack (26) on two radio rack mounting brackets (12) with two screws (23),
16. Install front radio rack (26) on plenum panel (1) and upper radio rack brackets (2) with two
washers (19) and locknuts (18).
17. Install two screws (20) and nuts (21) through “P” clamps (22) and front radio rack (26).
12-204.4 Change 1
TM 9-2320-280-20-3
Change 1 12-205
TM 9-2320-280-20-3
12-133. FRONT LOWER RADIO RACK REPLACEMENT

This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 Six locknuts (Appendix G, Item 106)
Tools
a. Removal
1. Remove two capscrews (2) and washers (3) from upper radio rack (1) and plenum (4).
2. Remove two locknuts (6), washers (5), and screws (12) from lower radio rack (8) and upper radio
rack (1). Discard locknuts (6).
3. Remove two locknuts (11), washers (10), capscrews (7), and upper radio rack (1) from mounting
4. Remove four locknuts (19), washers (14), capscrews (13), washers (14), and mounting brackets (9)
from lower radio rack (8). Discard locknuts (19).
5. Remove two locknuts (18), washers (15), capscrews (16), and lower radio rack (8) from mounting
b. Installation
1. Install lower radio rack (8) on mounting brackets (17) with two capscrews (16), washers (15), and
locknuts (18). Tighten locknuts (18) to 8-10 lb-ft (11-14 NŽm).
2. Install two mounting brackets (9) on lower radio rack (8) with four washers (14), capscrews (13),
washers (14), and locknuts (19). Finger tighten locknuts (19).
3. Install upper radio rack (1) on mounting brackets (9) with two capscrews (7), washers (10), and
locknuts (11). Tighten locknuts (11) to 8-10 lb-ft (11-14 NŽm).
4. Install upper radio rack (1) on lower radio rack (8) with two screws (12), washers (5), and
locknuts (6).
5. Install upper radio rack (1) on plenum (4) with two washers (3) and capscrews (2). Tighten
capscrews (2) to 6 lb-ft (8 NŽm).
6. Tighten four locknuts (19) on mounting brackets (9) and lower radio rack (8).
12-206
TM 9-2320-280-20-3
12-134. DUAL TSEC/KY-57 MOUNTING BRACKET AND CONTROL SWITCH BRACKET

REPLACEMENT
This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1, M1097, Four locknuts (Appendix G, Item 76)
M1097A1, M1097A2 Manual References
Tools TM 9-2320-280-24P
a. Removal
Remove four locknuts (6), washers (3), capscrews (2), washers (3), dual TSEC/KY-57 mounting bracket (4)
and control switch bracket (5) from radio rack (1). Discard locknuts (6).
b. Installation
Install switch bracket (5) and mounting bracket (4) on radio rack (1) with four washers (3), capscrews (2),
12-207
TM 9-2320-280-20-3
12-135. SPEAKER STOP REPLACEMENT

This task covers:
lNITIAL SETUP:
a. Removal
Remove two locknuts (4), washers (2), capscrews (1), washers (2), and speaker stop (3) from auxiliary
shelf (5). Discard locknuts (4).
b. Installation
Install speaker stop (3) on auxiliary shelf (5) with two washers (2), capscrews (1), washers (2), and
locknuts (4).
12-208
TM 9-2320-280-20-3
12-136. ANTENNA GROUND STRAP REPLACEMENT

This task covers:
INITIAL SETUP:
M997A1, M997A2, M1036, M1037, M1042, TM 9-2320-280-24P
M1097, M1097A1, M1097A2
Equipment Condition
General mechanic’s tool kit: M966, M966A1, M1025, M1025A1, M1025A2,
automotive (Appendix B, Item 1) M1026, M1026A1, M1043, M1043A1, M1043A2,
M1044, M1044A1, M1045, M1045A1, M1045A2,
Materials/Parts M1046, and M1046A1 only:
Antiseize compound (Appendix C, Item 13) Ž Cargo shell door raised (TM 9-2320-280-10).
a. Removal
1. Remove screw (6), lockwasher (7), and ground strap (3) from antenna base (2). Discard lockwasher (7).
NOTE
Perform step 2 for M998, M998A1, M1035, M1035A1, M1035A2
M1038, and M1038A1 models only.
2. Remove locknut (4), lockwasher (5), screw (8), and ground strap (3) from antenna mounting bracket
assembly (1). Discard locknut (4) and lockwasher (5).
NOTE
Perform step 3 for M966, M966A1, M1025, M1025A1, M1025A2, M1026,
M1026A1, M1043, M1043A1, M1043A2, M1044, M1044A1, M1045,
M1045A1, M1045A2, M1046, and M1046A1 models only.
3. Remove locknut (13), washer (10), capscrew (9), washer (10), ground strap (3), and lockwasher (12)
from cargo shell (11). Discard locknut (13) and lockwasher (12).
12-209
TM 9-2320-280-20-3
12-136. ANTENNA GROUND STRAP REPLACEMENT (Cont’d)

b. Installation
NOTE
Perform step 1 for M966, M966A1, M1025, M1025A1, M1025A2,
M1026, M1026A1, M1045A2, M1043, M1043A1, M1043A2, M1044,
M1044A1, M1045, M1045A1, M1046, and M1046A1 models only.
1. Install lockwasher (12) and ground strap (3) on cargo shell (11) with washer (10), capscrew (9),
washer (10), and locknut (13). Tighten locknut (13) to 31 lb-ft (42 NŽm).
NOTE
M1035A2, M1038, and M1038A1 models only.
2. Apply antiseize compound to screw (8) threads.
3. Install lockwasher (5) and ground strap (3) on antenna mounting bracket assembly (1) with
screw (8) and locknut (4).
4. Install ground strap (3) on antenna base (2) with lockwasher (7) and screw (6).

M966, M966A1, M1025, M1025A1, M1025A2, M1026, M1026A1, M1043, M1043A1,
M1043A2, M1044, M1044A1, M1045, M1045A1, M1045A2, M1046, and M1046A1
only:
Ž Lower cargo shell door (TM 9-2320-280-10).
12-210
TM 9-2320-280-20-3
12-137. AS 1729/VRC ANTENNA REPLACEMENT

This task covers:
INITIAL SETUP:
AU models except M996, M996A1, M1036, TM 9-2320-280-24P
M1037, M1042, M1097, M1097A1, M1097A2
Equipment Condition
Tools Antenna ground strap removed (para. 12-136)
General mechanic’s tool kit: (except M997, M997A1, M997A2)
Materials/Parts
NOTE
Antenna replacement is basically the same for all models except

the M998, M998A1, M1038, and M1038A1 which use an external
antenna mounting bracket. This procedure covers the M966,
M966A1, M997, M997A1, M997A2, M1025, M1025A1, M1025A2,
M1026, M1026A1, M1035, M1035A1, M1035A2, M1043, M1043A1,
M1043A2, M1044, M1044A1, M1045, M1045A1, M1045A2, M1046,
and M1046A1 models.
a. Removal
1. Disconnect radio antenna cable (3) and antenna control cable (2) from antenna (1).
2. Remove three locknuts (6), washers (5), capscrews (4), washers (5), and antenna (1) from cargo
shell (7). Discard locknuts (6).
1. Install antenna (1) on cargo shell (7) with three washers (5), capscrews (4), and locknuts (6). Tighten
locknuts (6) to 26 lb-ft (35 NŽm).
2. Connect antenna control cable (2) and radio antenna cable (3) on antenna (1).
FOLLOW-ON TASK: Install antenna ground strap (para. 12-136).
12-211
TM 9-2320-280-20-3
12-138. REAR ANTENNA MOUNTING BRACKET REPLACEMENT

This task covers:
lNITIAL SETUP:
M998, M998A1, M1038, M1038A1 Three locknuts (Appendix G, Item 66)
Equipment Condition
Special Tools Ž AS 1729/VRC antenna removed (para. 12-137)
Crowfoot, 3/8 in. (Appendix B, Item 151) if installed.
Socket adapter, 3/8 in. (Appendix B, Item 146) Ž AB-652/GR antenna removed (para. 12-139)
if installed.
a. Removal
1. Remove grommet (3).

NOTE
Note position of washers and clamp for installation.
2. Remove three locknuts (8), washers (7), capscrews (4), washers (5), antenna mounting bracket (2),
and clamp (6) from body (1). Discard locknuts (8).
b. Installation
1. Install antenna mounting bracket (2) and clamp (6) on body (1) with three washers (5),
capscrews (4), washers (7), and locknuts (8). Using crowfoot, tighten locknuts (8) to 15 lb-ft (20 NŽm).
2. Install grommet (3).
FOLLOW-ON TASKS: Ž Install AS 1729/VRC antenna (para. 12-137) if removed.

Ž Install AB-652/GR antenna (para. 12-139) if removed.
12-212
TM 9-2320-280-20-3
12-139. AB-652/GR ANTENNA REPLACEMENT

This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-24P
General mechanic’s tool kit: Battery ground cable disconnected
Materials/Parts
a. Removal
1. Disconnect antenna cable (7) from adapter (8).

2. Loosen ground clamp (9) and remove from adapter (8).
3. Remove adapter (8) from lower insulator (10).
4. Remove antenna (1), rubber washer (13), ground ring (12), rubber washer (11), and lower
insulator (10) from antenna mounting bracket (5).
5. Remove four locknuts (6), washers (3), capscrews (2), washers (3), and adapter (4) from antenna
mounting bracket (5). Discard locknuts (6).
b. Installation
1. Install adapter (4) on antenna mounting bracket (5) with four washers (3), capscrews (2),
2. Install lower insulator (10), rubber washer (11), ground ring (12), rubber washer (13), and
antenna (1) on mounting bracket (5).
3. Install adapter (8) on lower insulator (10).
4. Install ground clamp (9) on adapter (8) and tighten.
5. Connect antenna cable (7) to adapter (8).
12-213
TM 9-2320-280-20-3
12-140. REAR ANTENNA CABLES REPLACEMENT

This task covers:
INITIAL SETUP:
M997A1, M997A2, M1037, M1042, M1097, TM 9-2320-280-24P
M1097A1, M1097A2
Equipment Condition
General mechanic’s tool kit: Ž Right rear passenger seat back removed
Ž Dual TSEC/KY-57 mounting bracket and control
Materials/Parts switch bracket removed (para. 12-134) if
Two tiedown straps (Appendix G, Item 242) installed.
Eleven nut and lockwasher assemblies Ž Front floorboard removed (para. 11-154).
(Appendix G, Item 146) M966, M966A1, M1025, M1025A1, M1025A2,
Three locknuts (Appendix G, Item 106) M1026, M1026A1, M1043, M1043A1, M1043A2,
Two lockwashers (Appendix G, Item 120) M1044, M1044A1, M1045, M1045A1, M1045A2,
M1046, and M1046A1 models only:
Personnel Required Ž Cargo shell door raised (TM 9-2320-280-10).
One mechanic
One assistant
NOTE
Ž Left and right rear antenna cables are replaced basically the
same, except the left antenna cables have an additional six
clamps securing cables across rear of vehicle. This procedure
covers the right rear antenna cables.
Ž Perform steps 1 through 5 for front radio rack, and steps 6 and 7
for rear radio rack.
a. Removal
1. Remove two tiedown straps (6) from antenna cables (4). Discard tiedown straps (6).
2. Remove two nut and lockwasher assemblies (5), screws (2), two clamps (3), and antenna cables (4)
from front radio rack (1). Discard nut and lockwasher assemblies (5).
3. Remove nut and lockwasher assembly (11), capscrew (8), clamp (9) from two antenna cables (4), and
grommet (10). Discard nut and lockwasher assembly (11).
4. Remove two screws (12) and insulation retainer (13) from cargo floor (7) and pull away from cargo
floor (7).
5. Remove three screws (26), clamps (27), and two antenna cables (4) from body (19).
6. Remove two capscrews (23), washers (24), clamps (25), and antenna cables (18) from rear radio
rack (22) and cargo floor (7).
7. Remove two screws (20), clamps (21), and antenna cables (18) from body (19) and remove
clamps (21) from antenna cables (18).
8. Remove nut and lockwasher assembly (28), screw (17), and clamp (29) from two antenna cables (4)
and body (19). Discard nut and lockwasher assembly (28).
9. Remove two nut and lockwasher assemblies (14), capscrews (30), antenna cables (4), grommet (16),
and retainer (15) from body (19). Discard nut and lockwasher assemblies (14).
12-214
TM 9-2320-280-20-3
12-140. REAR ANTENNA CABLES REPLACEMENT (Cont’d)
12-215
TM 9-2320-280-20-3

10. Remove five screws (7), clamps (3), and two antenna cables (1) from underbody (2).
11. Remove locknut (5), washer (4), capscrew (9), washer (4), and filler pipe clamp (8) from
underbody (2) and tiller pipe (6). Discard locknut (5).
NOTE
Perform steps 12 through 15 for M966, M966A1, M1025, M1025A1,
M1025A2, M1026, M1026A1, M1043, M1043A1, M1043A2, M1044,
M1044A1, M1045, M1045A1, M1045A2, M1046, and M1046A1
models only.
12. Remove two locknuts (10), screws (12), clamps (11), and antenna cables (1) from wheelhouse (13).
13. Remove two nut and lockwasher assemblies (18), capscrews (15), two antenna cables (1), grommet
(17), and retainer (16) from wheelhouse (13). Discard nut and lockwasher assemblies (18).
14. Disconnect two antenna cables (1) from antenna base (14) and remove antenna cables (1).
15. Remove ten clamps (3) and two clamps (11) from antenna cables (1).
12-216
TM 9-2320-280-20-3

NOTE
Perform steps 16 through 22 for M998, M998A1, M1038, and
M1038A1 models only.
16. Remove nut and lockwasher assembly (23), capscrew (25), clamp (26), two antenna cables (1), and
body harness (24) from body (22). Discard nut and lockwasher assembly (23).
17. Remove two capscrews (28) and lockwashers (27) from cable shield (21) and body (22). Pull cable
shield (21) away from body (22) to allow access to clamps (30). Discard lockwashers (27).
18. Remove two nut and lockwasher assemblies (29), capscrews (20), clamps (30), antenna cables (1),
and body harness (24) from cable shield (21). Discard nut and lockwasher assemblies (29).
NOTE
Note position of clamp for installation.
19. Remove nut (18), clamp (31), and two antenna cables (1) from antenna mounting bracket cap
screw (19). Discard nut (18).
20. Disconnect two antenna cables (1) from antenna base (14), and push grommet (33) and antenna
cables (1) through grommet opening (32) in body (22). Remove grommet (33) from antenna cables (1).
21. Remove antenna cables (1).
22. Remove clamps from two antenna cables (1) and body harness (24) as required.
b. Installation
1. Install two antenna cables (1) in approximate mounting location.

2. Inatall clamps and grommet (33) on two antenna cables (1) and body harness (24) as required.
NOTE
Perform steps 3 through 8 for M998, M998A1, M1038, and
M1038A1 models only.
3. Insert antenna cables (1) through grommet opening (32) and install grommet (33) in body (22).
4. Connect antenna cables (1) to antenna base (14).
5. Install two antenna cables (1) on antenna mounting bracket capscrew (19) with clamp (31) and nut (18).
6. Install two antenna cables (1) and body harness (24) on shield (21) with two clamps (30), cap-
7. Install shield (21) on body (22) with two lockwashers (27) and capscrews (28).
8. Secure two antenna cables (1) and body harness (24) to body (22) with clamp (26), capscrew (25), and
nut and lockwasher assembly (23).
12-217
TM 9-2320-280-20-3

NOTE
Perform steps 9 through 12 for M966, M966A1, M1025, M1025A1,
M1025A2, M1026, M1026A1, M1043, M1043A1, M1043A2, M1044,
M1044A1, M1045, M1045A1, M1045A2, M1046, and M1046A1
models only.
9. Connect two antenna cables (4) to antenna base (1).
10. Install grommet (5) and retainer (7) on antenna cables (4).
11. Install two antenna cables (4), grommet (5), and retainer (7) on wheelhouse (6) with two capscrews (2)
12. Install two antenna cables (4) on wheelhouse (6) with two clamps (9), screws (10), and locknuts (8).
13. Install two antenna cables (4) on underbody (12) with clamp (11) and screw (23).
14. Position clamp (20) over yellow locator tape (22) on two antenna cables (4) and install on underbody (12)
with screw (21).
15. Secure two antenna cables (4) to underbody (12) with three clamps (16) and screws (15).
16. Install clamp (17) on filler spout (19) and underbody (12) with washer (13), capscrew (18),
12-218
TM 9-2320-280-20-3

17. Install grommet (25) and retainer (24) on two antenna cables (4).
18. Install two antenna cables (4), grommet (25), and retainer (24) on body (28) with two capscrews (40)
19. Install two antenna cables (4) on body (28) with clamp (26), screw (27), and nut and lockwasher
assembly (39).
NOTE
Perform steps 20 and 21 for rear radio rack, and steps 22
through 27 for front radio rack.
20. Install antenna cables (29) and (32) on body (28) with two clamps (31) and screws (30).
21. Install antenna cables (29) and (32) on rear radio rack (36) with two clamps (35), washers (34), and
capscrews (33). Tighten capscrews (33) to 15 lb-ft (20 NŽm).
22. Secure two antenna cables (4) to body (28) with three clamps (38) and screws (37).
12-219
TM 9-2320-280-20-3

23. Route two antenna cables (9) under insulation (6) along cargo floor (1).
24. Install insulation retainer (8) on cargo floor (1) with two screws (7).
25. Install two antenna cables (9) and grommet (4) on cargo floor (1) with clamp (2), capscrew (3), and
26. Install two antenna cables (9) and power cable (14) on front radio rack (10) with two clamps (12),
27. Secure two antenna cables (9) to radio power cable (14) with two tiedown straps (15).
FOLLOW-ON TASKS: Ž Install right rear passenger seat back (para. 10-45).
Connect battery ground cable (para. 4-73).
Install dual TSEC/KY-57 mounting bracket and control switch bracket
(para. 12-134), if removed.
Install front floorboard (para. 11-154).
M966, M966A1, M1025, M1025A1, M1025A2, M1026, M1026A1, M1043, M1043A1,
M1043A2, M1044, M1044A1, M1045, M1045A1, M1045A2, M1046, and M1046A1
models only:
Ž Lower cargo shell door (TM 9-2320-280-10).
12-220
TM 9-2320-280-20-3
1 2 - 1 4 1 . FRONT RADIO RACK POWER CABLE REPLACEMENT

This task covers:
INITIAL SETUP:
All models except M996, M996A1, M997, Four nut and lockwasher assemblies
M997A1, M997A2, M1037, M1042, M1097, (Appendix G, Item 146)
M1097A1, M1097A2, M1123 Two lockwashers (Appendix G, Item 120)
Two tiedown straps (Appendix G, Item 239)
Tools Two locknuts (Appendix G, Item 107.2)
TM 9-2320-280-24P
Equipment Condition
a. Removal
1. Remove two tiedown straps (16) from power cable (9) and antenna cables (4). Discard tiedown straps (16).
2. Remove two nut and lockwasher assemblies (8), screws (5) clamps (7), and power cable (9) from radio
rack (1). Discard nut and lockwasher assemblies (8).
3. Remove two capscrews (2) and washers (3) from radio rack (1) and “A” beam (6). Pull radio
rack (1) away from “A” beam (6).
NOT E
Perform step 3.1 for vehicles with new configuration.
3.1. Remove two locknuts (29), washers (28), radio rack (1), capscrews (26), washers (27), and radio rack
upper brackets (30) from “A” beam (6). Discard locknuts (29).
4. Remove engine access cover (para. 10-15).
5. Remove two nut and lockwasher assemblies (12) and capscrews (15) from clamp (14), retainer (11),
grommet (10), power cable (9), and body (13). Discard nut and lockwasher assemblies (12).
6. Remove nut (20), lockwasher (19), washer (18), and positive lead (17) from stud (25). Discard
lockwasher (19).
7. Remove nut (21), lockwasher (22), and negative lead (23) from shunt (24). Discard lockwasher (22).
8. Remove power cable (9).
Change 1 12-221
TM 9-2320-280-20-3
1 2 - 1 4 1 . FRONT RADIO RACK POWER CABLE REPLACEMENT( C o n t ’ d )
b. Installation
1. Position power cable (9) in approximate location.

2. Install negative lead (23) to shunt (24) with lockwasher (22) and nut (21). Tighten nut (21) to 75 lb-ft
(102 N•m).
3. Install positive lead (17) on power stud (25) with washer (18), lockwasher (19), and nut (20). Tighten
nut (20) to 26 lb-ft (35 N•m).
4. Install grommet (10), retainer (11), clamp (14), and power cable (9) on body (13) with two
capscrews (15) and nut and lockwasher assemblies (12). Tighten capscrews (15) to 5 lb-ft (7 N•m).
5. Install engine access cover (para. 10-15).
NOT E
Perform step 5.1 for vehicles with new configuration.
5.1. Install radio rack (1) and two radio rack upper brackets (30) on “A” beam (6) with two washers (28),
locknuts (29), washers (27), and capscrew (26).
6. Install radio rack (1) on “A” beam (6) with two washers (3) and capscrews (2). Tighten capscrews (2)
to 6 lb-ft (8 N•m).
7. Install power cable (9) on antenna cables (4) with two tiedown straps (16).
8. Install power cable (9) on radio rack (1) with two clamps (7), screws (5), and nut and lockwasher
assemblies (8).
12-222 Change 1
TM 9-2320-280-20-3
1 2 - 1 4 1 . FRONT RADIO RACK POWER CABLE REPLACEMENT (C

ont’d )
NEW CONFIGURATION
Change 1 12-222.1/(12-222.2 blank)

TM 9-2320-280-20-3
12-142. HEADPHONE MOUNTING BRACKET REPLACEMENT

This task covers:
INITIAL SETUP:
Materials/Parts
a. Removal
Remove two locknuts (4), washers (3), screws (1), and headphone mounting bracket (5) from radio
b. Installation
Install headphone mounting bracket (5) on radio rack (2) with two screws (1), washers (3), and
12-223
TM 9-2320-280-20-3
12-143. HANDSET BRACKET REPLACEMENT

This task covers:
INITIAL SETUP:

a. Removal
Remove two locknuts (5), washers (3), capscrews (2), washers (3), and handset bracket (4) from upper
shelf (1). Discard lockuts (5).
b. Installation
Install handset bracket (4) on upper shelf (1) with two washers (3), capscrews (2), washers (3), and
12-224
TM 9-2320-280-20-3
12-144. REAR RADIO RACK MAINTENANCE

This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-24P
General mechanic’s tool kit: Ž Speaker stop removed (para. 12-135) if installed.
automotive (Appendix B, Item 1) Ž Handset brackets removed (para. 12-143).
Materials/Parts
a. Removal
1. Remove two locknuts (9), washers (10), capscrews (12), washers (10), and insulation retainer (11)
from radio rack (2). Discard locknuts (9).
2. Remove two screws (16), retainer (15), and insulation (14) from cargo floor (8) and left brace (13),
and pull insulation (14) and two left antenna cables (1), if present, away from radio rack (2).
3. Remove two locknuts (7), washers (4), capscrews (5), washers (4), power cable (3), and two clamps (6)
12-225
TM 9-2320-280-20-3
12-144. REAR RADIO RACK MAINTENANCE (Cont’d)

4. Remove two capscrews (36), washers (37), antenna cables (14), clamps (38), and radio rack (17) from
cargo floor (23).
5. Remove two capscrews (35), washers (34), cargo tiedowns (33), and radio rack braces (29) from cargo
floor (23).
6. Remove two capscrews (16), washers (15), and radio rack (17) from cargo floor (23).
b. Disassembly
1. Remove four locknuts (7), washers (8), capscrews (10), washers (8), and two braces (9) from
supports (6). Discard locknuts (7).
2. Remove three locknuts (12), washers (4), capscrews (3), washers (4), and two braces (13) from
shelves (5). Discard locknuts (12).
3. Remove seven locknuts (11), washers (1), capscrews (2), washers (1), and two shelves (5) from
supports (6). Discard locknuts (11).
c. Assembly
NOTE
Assemble shelves to supports with holes designated “A” facing in
the same direction.
1. Install two shelves (5) on supports (6) with seven washers (1), capscrews (2), washers (1), and
2. Install two braces (13) on shelves (5) with three washers (4), capscrews (3), washers (4), and
3. Install two braces (9) on supports (6) with four washers (8), capscrews (10), washers (8), and
12-226
TM 9-2320-280-20-3
12-144. REAR RADIO RACK MAINTENANCE (Cont’d)

d. Installation
1. Install radio rack (17) on cargo floor (23) with two washers (15) and capscrews (16). Do not tighten
capscrews (16).
2. Secure two radio rack braces (29) to cargo floor (23) with two cargo tiedowns (33), washers (34), and
capscrews (35). Do not tighten capscrews (35).
3. Install two clamps (38) and antenna cables (14) on radio rack (17) with two washers (37) and
capscrews (36).
4. Tighten capscrews (36) and (16) securely. Tighten capscrews (26) to 15 lb-ft (20 NŽm). Tighten
5. Install two clamps (21) and power cable (18) on radio rack (17) with two washers (19), cap-
screws (20), washers (19), and locknuts (22). Tighten capscrews (20) to 15 lb-ft (20 NŽm).
6. Ensure left antenna cable(s) (14), if present, are routed under insulation (30). Install retainer (31)
and insulation (30) on cargo floor (23) and left brace (29) with two screws (32).
7. Install insulation retainer (27) on radio rack (17) with two washers (25), capscrews (28),
washers (25), and locknuts (24). Tighten capscrews (28) to 15 lb-ft (20 NŽm).
FOLLOW-ON TASK: Ž Install handset brackets (para. 12-143).

Ž Install speaker stop (para. 12-135) if removed.
12-227
TM 9-2320-280-20-3
12-145. REAR RADIO RACK ANTENNA TOWER MAINTENANCE

This task covers:L
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-24P
General mechanic’s tool kit: Antenna removed (para. 12-137 or 12-139).
Materials/Parts
Ten lockwashers (Appendix G, Item 110)
a. Removal
1. Remove three nuts (12), lockwashers (13), three clamps (14), and two antenna cables (17) from
capscrews (2). Discard lockwashers (13).
NOTE
If cargo soft top is installed, it will be necessary to unfasten and
roll up side for access to antenna tower mounting hardware.
2. Remove three nuts (11), washers (10), capscrews (18), washers (10), from tower (4) and
wheelhouse (7).
3. Remove two nuts (9), washers (6), half moon washers (8), capscrews (5), washers (6), and tower (4)
from wheelhouse (7).
b. Disassembly
Remove seven nuts (15), lockwashers (16), washers (3), capscrews (2), washers (3), and reinforcement (1)
from tower (4). Discard lockwashers (16).
c. Assembly
Install reinforcement (1) on tower (4) with seven washers (3), capscrews (2), washers (3),
lockwashers (16), and nuts (15). Tighten nuts (15) to 5 lb-ft (7 NŽm).
d. Installation
1. Install antenna tower (4) on wheelhouse (7) with two washers (6), capscrews (5), half moon
washers (8), washers (6), and nuts (9). Tighten nuts (9) to 5 lb-ft (7 NŽm).
2. Secure antenna tower (4) to wheelhouse (7) with three washers (10), capscrews (18), washers (10),
and nuts (11). Tighten nuts (11) to 45 lb-ft (61 NŽm).
3. Install two antenna cables (17) on wheelhouse (7) and capscrews (2) with three clamps (14),
12-228
TM 9-2320-280-20-3
12-145. REAR RADIO RACK ANTENNA TOWER MAINTENANCE (Cont’d)
FOLLOW-ON TASK: Install antenna (para. 12-137 or 12-139).
12-229
TM 9-2320-280-20-3
12-146. REAR RADIO RACK TO TOWER ANTENNA CABLES REPLACEMENT

This task covers:
INITIAL SETUP:
Tools
a. Removal
NOTE
Antenna cables from rear radio rack to left or right antenna towers
are replaced basically the same. This procedure covers the left
antenna cables.
1. Remove two locknuts (7), washers (8), capscrews (10), washers (8), and insulation retainer (9) from
radio rack (5). Discard locknuts (7).
2. Remove two screws (1) and retainer (2) from cargo floor (6) and left brace (11) and pull insulation (3)
away from radio rack (5).
3. Remove three screws (13), clamps (14), and two antenna cables (4) from wheelhouse (16) and cargo
floor (6).
4. Remove three nuts (17), lockwashers (18), clamps (15), and two antenna cables (4) from tower
capscrews (19). Discard lockwashers (18).
5. Disconnect two antenna cables (4) from antenna (12).
b. Installation
1. Connect two antenna cables (4) to antenna (12) and route in approximate mounting location.
2. Install three clamps (15) and antenna cables (4) on tower capscrews (19) with three lockwashers (18)
and nuts (17).
3. Install three clamps (14) on two antenna cables (4) and install three clamps (14) on wheelhouse (16)
with screws (13).
4. Route antenna cables (4) under insulation (3) and install insulation (3) and retainer (2) on cargo
floor (6) and left brace (11) with two screws (1).
5. Install insulation retainer (9) on radio rack (5) with two washers (8), capscrews (10) washers (8), and
locknuts (7). Tighten capscrews (10) to 15 lb-ft (20 NŽm).
12-230
TM 9-2320-280-20-3
12-146. REAR RADIO RACK TO TOWER ANTENNA CABLES REPLACEMENT (Cont’d)
12-231
TM 9-2320-280-20-3
12-147. REAR RADIO RACK POWER CABLE REPLACEMENT
This task covers:
INITIAL SETUP:
Tools
One assistant

Three lockwashers (Appendix G, Item 127) Battery ground cable disconnected (para. 4-73).
a. Removal
1. Remove two locknuts (6), washers (4), capscrews (3), washers (4), power cable (1), and clamps (2)
2. Remove two screws (8), clamps (7), power cable (1), and two antenna cables (12), if present, from
tunnel (11).
3. Remove grommet (9) from body (10) and power cable (1).
NOTE
It maybe necessary to loosen front shunt mounting bolt to remove
capscrew from shunt.
4. Remove nut (13), lockwasher (14), negative starter cable (15), nut (16), lockwasher (17),
capscrew (24), and power cable negative terminal (19) from shunt (18). Discard lockwashers (14)
and (17).
5. Remove nut (23), lockwasher (22), and power cable positive terminal (21) from power stud (20).
12-232
TM 9-2320-280-20-3
12-147. REAR RADIO RACK POWER CABLE REPLACEMENT (Cont’d)
12-233
TM 9-2320-280-20-3
12-147. REAR RADIO RACK POWER CABLE REPLACEMENT (Cont’d)
b. Installation
1. Install power cable (1) on approximate mounting location. Install locator tape (5) on power cable (1)
in grommet (4), and install grommet (4) on body (6).
2. Install positive terminal (17) on power stud (16) with lockwasher (18) and nut (19). Tighten nut (19)
to 26 lb-ft (35 NŽm).
3. Install negative terminal (15) on shunt (14) with capscrew (20), lockwasher (13), and nut (12).
Tighten nut (12) to 75 lb-ft (102 NŽm).
4. Install negative starter cable (11) to capscrew (20) with lockwasher (10) and nut (9). Tighten nut (9)
to 75 lb-ft (102 NŽm).
5. Install two clamps (2) on power cable (1) and two antenna cables (8), if present, and install on tunnel
(7) with two screws (3).
6. Install two clamps (21) on power cable (1) and install on radio rack (24) with two washers (23),
capscrews (22), washers (23), and locknuts (25). Tighten capscrews (22) to 15 lb-ft (20 NŽm).
12-234
TM 9-2320-280-20-3
Section VIII. 81 MM MORTAR KIT MAINTENANCE
12-148. 81 MM MORTAR KIT MAINTENANCE TASK SUMMARY
TASK PAGE
PROCEDURES
PARA. NO.
12-149. Mortar Ammo Container Maintenance 12-236

12-150. Base Plate Strap Replacement 12-240
12-151. Cleaning Staff Stowage Clip Replacement 12-241
12-152. Bipod Stowage Tray Maintenance 12-242
12-153. Ready Rack Replacement 12-244
12-154. Ready Rack Strap Replacement 12-245
12-155. Ready Rack Hand Guard Replacement 12-246
12-156. Equipment Rack Replacement 12-247
12-157. Tool Chest Strap Replacement 12-248
12-158. Troop Seat Support Pad Replacement 12-249
12-159. Mortar Barrel Stowage Bracket Replacement 12-250
12-235
TM 9-2320-280-20-3
12-149. MORTAR AMMO CONTAINER MAINTENANCE

This task covers:
INITIAL SETUP:
One assistant
Tools
TM 9-2320-280-24P
Materials/Parts
Tape (Appendix C, Item 50) Equipment Condition
Sixteen locknuts (Appendix G, Item 65) Ž Ready rack straps removed (para. 12-154).
Six locknuts (Appendix G, Item 69) Ž Base plate strap removed (para. 12-150).
Thirty locknuts (Appendix G, Item 58) Ž Tailgate lowered (TM 9-2320-280-10).
Twenty locknuts (Appendix G, Item 78) Ž Cargo bulkhead removed (para. 10-53).
a. Removal
1. Remove four capscrews (3) and washers (4) from ammo container (2) and cargo floor (6).
2. Remove two locknuts (7), washers (8), capscrews (1), and washers (8) from ammo container (2) and
3. Remove ammo container (2) and twenty-four washers (5) from cargo floor (6).
4. Remove tape from ammo container (2).
12-236
TM 9-2320-280-20-3
12-149. MORTAR AMMO CONTAINER MAINTENANCE (Cont’d)

b. Disassembly
1. Remove twelve locknuts (23), washers (21), capscrews (20), washers (21), and six footman loops (19)
from ammo container supports (17). Discard locknuts (23).
2. Remove twelve locknuts (15), washers (16), capscrews (18), washers (16), six ammo container
supports (17), and three straps (19) from ammo container (2). Discard locknuts (15).
3. Remove two locknuts (38), washers (37), capscrews (35), and strap bracket (36) from ammo
container (2). Discard locknuts (38).
4. Remove four locknuts (31), washers (32), capscrews (34), and two base plate brackets (33) from
ammo container (2). Discard locknuts (31).
5. Remove four locknuts (30), washers (29), capscrews (27), and four tiedown brackets (28) from ammo
container base (25). Discard locknuts (30).
6. Remove twenty locknuts (10), washers (11), capscrews (24), and two ammo container reinforce-
ments (9) from ammo container (2). Discard locknuts (10).
7. Remove sixteen locknuts (26), washers (13), capscrews (12), washers (13), ammo container
floor (14), and ammo container (2) from ammo base (25). Discard locknuts (26).
12-237
TM 9-2320-280-20-3
c. Assembly
1. Install ammo container (29) and ammo container floor (6) on ammo container base (16) with sixteen
washers (5), capscrews (4), washers (5), and locknuts (17). Tighten locknuts (17) to 15 lb-ft (20 NŽm).
2. Install two ammo container reinforcements (1) on ammo container (29) with twenty capscrews (7),
3. Install four tiedown brackets (19) on ammo container base (16) with four washers (20),
capscrews (18), and locknuts (21).
4. Install two base plate brackets (24) on ammo container (29) with two capscrews (25), washers (23),
5. Install strap bracket (27) on ammo container (29) with two capscrews (26), washers (30), and
6. Install three straps (14) and ammo container supports (8) on ammo container (29) with twelve
washers (9), capscrews (10), washers (9), and locknuts (28). Tighten locknuts (28) to 6 lb-ft (8 NŽm).
7. Install six footman loops (13) and three straps (14) on ammo container supports (8) with twelve
washers (12), capscrews (11), washers (12), and locknuts (15). Tighten locknuts (15) t O
6 lb-ft (8 N m).
12-238
TM 9-2320-280-20-3

d. Installation
1. Install twenty-four washers (36) and ammo container (33) on vehicle.

2. Install two washers (39), capscrews (32), washers (39), locknuts (38), and ammo container (33) on
cargo floor (37). Tighten capscrews (32) to 65 lb-ft (88 NŽm).
3. Install four washers (35), capscrews (34), and ammo container (33) on cargo floor (37). Tighten
FOLLOW-ON TASKS: Ž Install cargo bulkhead (para. 10-53).

Ž Install base plate strap (para. 12-150).
Ž Install ready rack straps (para. 12-154).
Ž Raise tailgate (TM 9-2320-280-10).
12-239
TM 9-2320-280-20-3
12-150. BASE PLATE STRAP REPLACEMENT

This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
Materials/Parts
a. Removal
1. Unlatch strap (7) from bracket (6).

2. Remove two locknuts (4), washers (2), capscrews (1), washers (2), footman loop (3), and strap (7)
from ammo rack container (5). Discard locknuts (4).
b. Installation
1. Install footman loop (3) and strap (7) on ammo rack container (5) with two washers (2), capscrews (1),
2. Latch strap (7) to bracket (6).
FOLLOW-ON TASK: Raise tailgate (TM 9-2320-280-10).
12-240
TM 9-2320-280-20-3
12-151. CLEANING STAFF STOWAGE CLIP REPLACEMENT

This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
Materials/Parts
NOTE
A shim is installed under front stowage clip.
a. Removal
1. Remove two screws (1) and clip (2) from cargo floor (3).
2. Remove tape from bottom of clip (2) (or bottom of shim for front clip).
b. Installation
1. Apply tape on bottom of clip (2) (or bottom of shim for front clip).
2. Install clip (2) on cargo floor (3) with two screws (1).
12-241
TM 9-2320-280-20-3
12-152. BIPOD STOWAGE TRAY MAINTENANCE

This task covers:
lNITIAL SETUP:
One assistant
Tools
Materials/Parts
Fifteen locknuts (Appendix G, Item 78)
a. Removal
1. Remove five locknuts (7), washers (8), capscrews (1), and washers (8) from bipod stowage
tray (2) and wheelhouse (3). Discard locknuts (7).
2. Remove three capscrews (6), lockwashers (5), washers (4), and bipod stowage tray (2) from
wheelhouse (3). Discard lockwashers (5).
3. Remove tape from bipod stowage tray (2).
b. Disassembly
1. Remove six locknuts (15), washers (13), capscrews (12), washers (13), and support bracket (14) from
tray (16). Discard locknuts (15).
2. Unlatch straps (9) from footman loops (21).
3. Remove four locknuts (18), washers (17), screws (11), two footman loops (10), and straps (9) from
tray (16). Discard locknuts (18).
4. Remove four locknuts (19), washers (20), screws (22), and two footman loops (21) from tray (16).
c. Assembly
1. Install two footman loops (21) on tray (16) with four screws (22), washers (20), and locknuts (19).
2. Install two footman loops (10) on two straps (9) and tray (16) with four screws (11), washers (17),
and locknuts (18).
3. Latch straps (9) to footman loops (21).
4. Install support bracket (14) on tray (16) with six washers (13), capscrews (12), washers (13), and
d. Installation
1. Apply tape to bipod stowage tray (2).

2. Install bipod stowage tray (2) on wheelhouse (3) with three washers (4), lockwashers (5), and
capscrews (6). Tighten capscrews (6) to 6 lb-ft (8 NŽm).
3. Secure bipod stowage tray (2) to wheelhouse (3) with five washers (8), capscrews (1), washers (8),
12-242
TM 9-2320-280-20-3
12-152. BIPOD STOWAGE TRAY MAINTENANCE (Cont’d)
12-243
TM 9-2320-280-20-3
12-153. READY RACK REPLACEMENT

This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-24P
Tools
a. Removal
Unlatch two straps (2) and remove ready rack (1) from cargo floor (3).
b. Installation
Install ready rack (1) on cargo floor (3) with two straps (2).
12-244
TM 9-2320-280-20-3
12-154. READY RACK STRAP REPLACEMENT

This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-24P
General mechanic’s tool kit: Ready rack removed (para. 12-153).
a. Removal
Remove two screws (2) securing footman loop (4) and strap (1) to ammo container (3) and remove footman
loop (4) from strap (1).
b. Installation
Install footman loop (4) and strap (1) on ammo container (3) with two screws (2).
FOLLOW-ON TASK: Install ready rack (para. 12-153).
12-245
TM 9-2320-280-20-3
12-155. READY RACK HAND GUARD REPLACEMENT

This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-24P
General mechanic’s tool kit: Ready rack removed (para. 12-153).
Materials/Parts
a. Removal
1. Remove hand guard (2) from ready rack (1).

2. Clean adhesive from ready rack (1).
b. Installation
Apply adhesive to hand guard (2) and ready rack (1). Install hand guard (2) on ready rack (1).
FOLLOW-ON TASK: Install ready rack (para. 12-153).
12-246
TM 9-2320-280-20-3
12-156. EQUIPMENT RACK REPLACEMENT

This task covers:
lNITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-24P
General mechanic’s tool kit: Ž Tool chest straps removed (para. 12-157).
automotive (Appendix B, Item 1) Ž Troop seat support pad removed (para. 12-158).
Materials/Parts
a. Removal
1. Remove six capscrews (3), lockwashers (4), and equipment rack (5) from cargo floor (6). Discard
lockwashers (4).
2. Remove two locknuts (1), washers (8), screws (7), and retainer bracket (2) from equipment
3. Remove tape from equipment rack (5).
b. Installation
1. Apply tape to equipment rack (5).

2. Install retainer bracket (2) on equipment rack (5) with two washers (8), screws (7), and locknuts (1).
3. Install equipment rack (5) on cargo floor (6) with six lockwashers (4) and capscrews (3). Tighten
capscrew (3) to 15 lb-ft (20 NŽm).
FOLLOW-ON TASKS: Ž Install troop seat support pad (para. 12-158).

Ž Install tool chest straps (para. 12-157).
12-247
TM 9-2320-280-20-3
12-157. TOOL CHEST STRAP REPLACEMENT

This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) Right troop seat raised (TM 9-2320-280-10).
Materials/Parts
a. Removal
NOTE
The tool chest strap, M14 chest strap, and M166 chest strap are
replaced basically the same. This procedure covers tool chest strap
replacement.
Remove four locknuts (5), screws (4), two footman loops (3), and strap (2) from equipment rack (1).
b. Installation
Install two footman loops (3) and strap (2) on equipment rack (1) with four screws (4) and locknuts (5).
FOLLOW-ON TASK: Lower right troop sear (TM 9-2320-280-10).
12-248
TM 9-2320-280-20-3
12-158. TROOP SEAT SUPPORT PAD REPLACEMENT

This task covers:
INITIAL SETUP:
M998, M998A1, M1038, M1038A1 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) Right troop seat raised (TM 9-2320-280-10).
Materials/Parts
a. Removal
Remove two locknuts (5), washers (3), capscrews (4), washers (3), and pad (2) from wheelhouse (1).
b. Installation
Install pad (2) on wheelhouse (1) with two washers (3), capscrews (4), washers (3), and locknuts (5).
FOLLOW-ON TASK: Lower right troop seat (TM 9-2320-280-10).
12-249
TM 9-2320-280-20-3
12-159. MORTAR BARREL STOWAGE BRACKET REPLACEMENT

This task covers:
INITIAL SETUP:
One assistant
Tools
TM 9-2320-280-24P
Materials/Parts
Tape (Appendix C, Item 50) Equipment Condition
Three locknuts (Appendix G, Item 58) Tailgate lowered (TM 9-2320-280-10).
a. Removal
1. Unlatch strap (1) from bracket (6).

2. Remove three locknuts (4), washers (3), capscrews (7), washers (3), bracket (6), and washer (5) from
3. Remove tape from bracket (6).
b. Installation
1. Apply tape to bracket (6).

2. Install washer (5) and bracket (6) on wheelhouse (2) with three washers (3), capscrews (7).
3. Latch strap (1) to bracket (6).
12-250
TM 9-2320-280-20-3
Section IX. TRAVERSING BAR KIT MAINTENANCE
12-160. TRAVERSING BAR KIT MAINTENANCE TASK SUMMARY
TASK PAGE
PROCEDURES
PARA. NO.
12-161. Traversing Bar Kit Maintenance 12-252
12-251
TM 9-2320-280-20-3
12-161. TRAVERSING BAR KIT MAINTENANCE

This task covers:
INITIAL SETUP:
Manual References
Applicable Models
M1043, M1043A1, M1043A2, M1044, TM 9-2320-280-24P
M1044A1 Equipment Condition
Tools Hatch opened (TM 9-2320-280-10).

Materials/Parts
NOTE
Ž This task covers the MK64 tri-mount and the .50 cal. machine
gun mount.
Ž Perform steps 1 and 2 for the MK64 mount only.
a. Removal
1. Remove two locknuts (12), washers (13), capscrews (1), washers (13), and traversing bar (2) from
upper mounts (6). Discard locknuts (12).
2. Remove four locknuts (3), washers (4), capscrews (7), washers (4), and upper mounts (6) from lower
mount (5). Discard locknuts (3).
NOTE
Perform steps 3 and 4 for the .50 cal. machine gun mount only.
3. Remove two locknuts (12), washers (13), capscrews (1), washers (13), and traversing bar (2) from
lower mount (5). Discard locknuts (12).
4. Remove three locknuts (9), washers (10), capscrews (11), washers (10), and lower mount (5) from
armament panel (8). Discard locknuts (9).
b. Installation
NOTE
Perform steps 1 and 2 for the .50 cal. machine gun mount only.
1. Install lower mount (5) on armament panel (8) with three washers (10), capscrews (11),
2. Install traversing bar (2) on lower mount (5) with two washers (13), capscrews (1), washers (13), and
NOTE
Perform steps 3 and 4 for the MK64 mount only.
3. Install upper mounts (6) on lower mount (5) with four washers (4), capscrews (7), washers (4), and
4. Install traversing bar (2) on upper mount (6) with two washers (13), capscrews (1), washers (13), and
12-252
TM 9-2320-280-20-3
12-161. TRAVERSING BAR KIT MAINTENANCE (Cont’d)
FOLLOW-ON TASK: Close hatch (TM 9-2320-280-10).
12-253
TM 9-2320-280-20-3
Section X. M1097, M1097A1, and M1097A2 SPECIAL PURPOSE KITS MAINTENANCE
12-162. M1097, M1097A1, AND M1097A2 SPECIAL PURPOSE KITS MAINTENANCE

TASK SUMMARY

PARA. NO.
12-163. Trailer Connector and Wiring Harness Replacement (L119) 12-255

12-164. Rear Bumper Replacement (L119) 12-257
12-165. Rear Bumper Brace Bracket Replacement (L119) 12-258
12-166. Rear Bumper Outer Brace Replacement (L119) 12-259
12-167. Rear Bumper Outer Mounting Bracket Replacement (L119) 12-260
12-168. Rear Bumper Inner Brace Replacement (L119) 12-261
12-169. Rear Bumper Inner Mounting Bracket Replacement (L119) 12-262
12-170. Pioneer Tool Stowage Rack Latch Strike Replacement (L119) 12-263
12-171. Rear Bumper Lifting Shackle Replacement (L119) 12-264
12-172. Rear Tiedown Bracket Replacement (L119) 12-265
12-173. Ammo Tiedown Strap Replacement (L119) 12-266
12-174. Ammo Divider Replacement (L119) 12-267
12-175. Telephone Strap Replacement (L119) 12-268
12-176. Section Chest Strap Replacement (L119) 12-269
12-177. Tripod Strap Replacement (L119) 12-270
12-178. Gun Display Unit Battery Strap Replacement (L119) 12-271
12-179. Sight Box Straps Replacement (L119) 12-272
12-180. Water/Fuel Can Strap Replacement (L119) 12-273
12-181. Ammo Rack Maintenance (L119) 12-274
12-182. M60 Machine Gun Strap Replacement (L119) 12-277
12-183. Camouflage Rack Maintenance 12-278
12-254
TM 9-2320-280-20-3
12-163. TRAILER CONNECTOR AND WIRING HARNESS REPLACEMENT (L119)

This task covers:
INITIAL SETUP:
M1097, M1097A1, M1097A2 TM 9-2320-280-24P
General mechanic’s tool kit: Battery ground cable disconnected (para. 4-73).
Materials/Parts
Four nut and lockwasher assemblies
NOTE
a. Removal
1. Remove four nut and lockwasher assemblies (13), capscrews (1), and receptacle cover (2) from
mounting bracket (4). Discard nut and lockwasher assemblies (13).
2. Remove nut and lockwasher assembly (7), capscrew (11), and clamp (9) from bracket (8). Discard nut
3. Disconnect receptacle assembly (3) from body wiring harness (10) and remove receptacle assembly (3).
4. Remove nut and lockwasher assembly (5), capscrew (12), and bracket (8) from "D" beam (6). Discard
12-255
TM 9-2320-280-20-3
12-163. TRAILER CONNECTOR AND WIRING HARNESS REPLACEMENT (L119) (Cont’d)
b. Installation
1. Install bracket (8) on “D” beam (6) with capscrew (12) and nut and lockwasher assembly (5).
2. Feed receptacle assembly (3) leads through bracket (8) and connect receptacle assembly (3) t O body
wiring harness (10).
3. Install clamp (9) and receptacle assembly (3) on bracket (8) with capscrew (11) and nut and
4. Install receptacle assembly (3) and receptacle cover (2) on mounting bracket (4) with four capscrews
(1) and nut and lockwasher assemblies (13).
12-256
TM 9-2320-280-20-3
12-164. REAR BUMPER REPLACEMENT (L119)

This task covers:
INITIAL SETUP:
M1097, M1097A1, M1097A2 Four locknuts (Appendix G, Item 79)
General mechanic’s tool kit: Ž Towing pintle removed (para 9-12).
automotive (Appendix B, Item 1) Ž Rear tiedown brackets (L119) removed
(para 12-172).
a. Removal
Remove four locknuts (6), washers (5), capscrews (3), washers (2), and bumper (4) from two inner
mounting brackets (1). Discard locknuts (6).
b. Installation
Install bumper (4) on two inner mounting brackets (1) with four washers (2), capscrews (3),
FOLLOW-ON TASKS: Ž Install rear tiedown brackets (L119) (para 12-172).

Ž Install towing pintle (para 9-12).
12-257
TM 9-2320-280-20-3
12-165. REAR BUMPER BRACE BRACKET REPLACEMENT (L119)

This task covers:
INITIAL SETUP:
M1097, M1097A1, M1097A2 TM 9-2320-280-10
General mechanic’s tool kit: Ž Pioneer tool stowage rack removed
Ž Towing pintle removed (para 9-12).
Materials/Parts
a. Removal
Remove four locknuts (6), washers (5), capscrews (3), washers (2) and brace bracket (4) from rear
bumper (7) and two inner braces (1). Discard locknuts (6).
b. Installation
1. Install brace bracket (4) on rear bumper (7) and two inner braces (1).
2. Secure brace bracket (4) to two inner braces (1) with four washers (2), capscrews (3), washers (5),
FOLLOW-ON TASKS: Ž Install towing pintle (para 9-12).

Ž Install pioneer tool stowage rack (TM 9-2320-280-10).
12-258
TM 9-2320-280-20-3
12-166. REAR BUMPER OUTER BRACE REPLACEMENT (L119)

This task covers:
INITIAL SETUP:
M1097, M1097A1, M1097A2 Three locknuts (Appendix G, Item 79)
a. Removal
1. Remove locknut (7), washer (8), capscrew (10), and washer (9) from outer brace (4) and frame (11).
2. Remove two locknuts (2), washers (3), capscrews (6), washers (5), and outer brace (4) from outer
mounting bracket (1). Discard locknuts (2).
b. Installation
1. Install outer brace (4) on outer mounting bracket (1) with two washers (5), capscrews (6),
2. Install outer brace (4) on frame (11) with washer (9), capscrew (10), washer (8), and locknut (7).
Tighten locknut (7) to 90 lb-ft (122 NŽm).
12-259
TM 9-2320-280-20-3
12-167. REAR BUMPER OUTER MOUNTING BRACKET REPLACEMENT (L119)

This task covers:
INITIAL SETUP:
M1097, M1097A1, M1097A2 TM 9-2320-280-24P
General mechanic’s tool kit: Rear tiedown bracket removed (para 12-172).
Materials/Parts
a. Removal
1. Remove two locknuts (2), washers (3), capscrews (7), and washers (6) from outer mounting
bracket (1) and outer brace (9). Discard locknuts (2).
2. Loosen locknut (8) from outer brace (9) and frame (10).
3. Remove four locknuts (11), washers (12), capscrews (4), washers (5), outer mounting bracket (1) and
spacer (13) from frame (10). Discard locknuts (11).
b. Installation
1. Install outer mounting bracket (1) and spacer (13) on frame (10) with four washers (5),
capscrews (4), washers (12), and locknuts (11). Tighten locknuts (11) to 90 lb-ft (122 NŽm).
2. Install outer mounting bracket (1) on outer brace (9) with two washers (6), capscrews (7), washers (3),
3. Tighten locknut (8) on outer brace (9) to 90 lb-ft (122 NŽm).
FOLLOW-ON TASKS: Install rear tiedown bracket (para 12-172).
12-260
TM 9-2320-280-20-3
12-168. REAR BUMPER INNER BRACE REPLACEMENT (L119)

This task covers:
lNITIAL SETUP:
M1097, M1097A1, M1097A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) Ž Pioneer tool stowage rack removed
(TM 9-2320-280-10).
Materials/Parts Ž Pioneer tool stowage rack latch strike removed
Three locknuts (Appendix G, Item 79) (para. 12-170).
a. Removal
1. Remove locknut (5), washer (4), capscrew (8), and washer (7) from inner brace (9) and frame (6).
2. Remove two locknuts (3), washers (2), capscrews (10), washers (11), and inner brace (9) from brace
b. Installation
1. Install inner brace (9) on brace bracket (1) with two washers (11), capscrews (10), washers (2), and
2. Install inner brace (9) on frame (6) with washer (7), capscrew (8), washer (4), and locknut (5).
Tighten locknut (5) to 90 lb-ft (122 NŽm).
FOLLOW-ON TASKS: Ž Install pioneer tool stowage rack latch strike (para. 12-170).
Ž Install pioneer tool stowage rack (TM 9-2320-280-10).
12-261
TM 9-2320-280-20-3
12-169. REAR BUMPER INNER MOUNTING BRACKET REPLACEMENT (L119)

This task covers:
INITIAL SETUP:
M1097, M1097A1, M1097A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) Pioneer tool stowage rack removed
(TM 9-2320-280-10).
Materials/Parts
a. Removal
1. Remove two locknuts (7), washers (8), capscrews (1), and washers (2) from inner mounting
bracket (10) and bumper (13). Discard locknuts (7).
2. Remove four locknuts (11), washers (12), capscrews (4), washers (3), inner mounting bracket (10),
and spacers (9) and (6) from frame (5).
b. Installation
1. Install inner mounting bracket (10) and spacers (9) and (6) on frame (5) with four washers (3),
2. Install inner mounting bracket (10) on bumper (13) with two washers (2), capscrews (1), washers (8),
FOLLOW-ON TASK: Install pioneer stowage rack (TM 9-2320-280-10).
12-262
TM 9-2320-280-20-3
12-170. PIONEER TOOL STOWAGE RACK LATCH STRIKE REPLACEMENT (L119)

This task covers:
INITIAL SETUP:
M1097, M1097A1, M1097A2 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) Pioneer tool stowage rack removed
(TM 9-2320-280-10).
Materials/Parts
a. Removal
Remove two nuts (5), lockwashers (4), screws (2), and latch strike (3) from rear bumper inner
brace (1). Discard lockwashers (4).
b. Installation
Install latch strike (3) on rear bumper inner brace (1) with two screws (2), lockwashers (4), and nut (5).
FOLLOW-ON TASK: Install pioneer tool stowage rack (TM 9-2320-280-10).
12-263
TM 9-2320-280-20-3
12-171. REAR BUMPER LIFTING SHACKLE REPLACEMENT (L119)

This task covers:
INITIAL SETUP:
M1097, M1097A1, M1097A2 Cotter pin (Appendix G, Item 18)
a. Removal
Remove cotter pin (6), slotted nut (1), spring washer (5), capscrew (3), and shackle (4) from tiedown
bracket (2). Discard cotter pin (6).
b. Installation
1. Install shackle (4) on tiedown bracket (2) with capscrew (3), spring washer (5), and slotted nut (1).
Tighten slotted nut (1) enough to allow movement of shackle (4).
2. Install cotter pin (6) on slotted nut (1).
12-264
TM 9-2320-280-20-3
12-172. REAR TIEDOWN BRACKET REPLACEMENT (L119)

This task covers:
INITIAL SETUP:
M1097, M1097A1, M1097A2 Two locknuts (Appendix G, Item 70)
Manual References
Tools
TM 9-2320-280-24P
Rear bumper lifting shackle (L119) removed
(para. 12-171).
a. Removal
Remove two locknuts (4), washers (3), capscrews (6), washers (5), and tiedown bracket (2) from rear
bumper (1).
b. Installation
Install tiedown bracket (2) on rear bumper (1) with two washers (5), capscrews (6), washers (3), and
locknuts (4). Tighten locknuts (4) to 90 lb-ft (122 N m).
FOLLOW-ON TASK: Install rear bumper lifting shackle (L119) (para. 12-171).
12-265
TM 9-2320-280-20-3
12-173. AMMO TIEDOWN STRAP REPLACEMENT (L119)

This task covers:
INITIAL SETUP:

Personnel Required
One mechanic
One assistant
a. Removal
1. Remove two locknuts (1), washers (9), reinforcement (11), screws (8), washers (9), and footman
loop (10) from strap (5) and wheelhouse (2). Discard locknuts (1).
2. Slide strap (5) through footman loop (3) on wedge (4).
3. Remove strap hook (6) from slot in ammo rack assembly (7) and remove strap (5).
b. Installation
1. Slide strap (5) on footman loop (10). Install footman loop (10) and strap (5) on wheelhouse (2) with
two washers (9), screws (8), reinforcement (11), washers (9), and locknuts (1).
2. Install strap (5) through footman loop (3) on wedge (4).
3. Attach strap hook (6) to slot in ammo rack assembly (7).
12-266
TM 9-2320-280-20-3
12-174. AMMO DIVIDER REPLACEMENT (L119)

This task covers:
INITIAL SETUP:
M1097, M1097A1, M1097A2 TM 9-2320-280-24P
Equipment Condition
Tools
General mechanic’s tool kit: Ammo tiedown strap removed (para. 12-173).
a. Removal
Remove two capscrews (2), washers (1), and ammo divider (3) from cargo floor (4).
b. Installation
Install ammo divider (3) on cargo floor (4) with two washers (1) and capscrews (2).
FOLLOW-ON TASK: Install ammo tiedown strap (para. 12-173).
12-267
TM 9-2320-280-20-3
12-175. TELEPHONE STRAP REPLACEMENT (L119)

This task covers:
INITIAL SETUP:
Personnel Required
Applicable Models
One assistant
Tools
TM 9-2320-280-24P
Materials/Parts
TWO locknuts (Appendix G, Item 89) Equipment Conditon
Troop seat (R..H.) raised (TM 9-2320-280-10).
NOTE
The telephone strap, remote strap, and cable reel strap are
replaced basically the same. This procedure covers the telephone
strap replacement.
a. Removal
1. Remove two locknuts (8), washers (7), and screws (4) footman loop (5), and strap (3) from fixed
2. Remove strap hook (1) from footman loop (2) and remove strap (3).
b. Installation
1. Slide strap (3) onto footman loop (5). Install footman loop (5) and strap (3) on fixed door (6) with two
2. Attach strap hook (1) on footman loop (2).
12-268
TM 9-2320-280-20-3
12-176. SECTION CHEST STRAP REPLACEMENT (L119)

This task covers:
INITIAL SETUP:
M1097, M1097A1, M1097A2 TM 9-2320-280-24P
Tools

NOTE
The section chest straps, aiming post straps, and spade straps are
replaced basically the same. This procedure covers the section
chest strap.
a. Removal
Remove two screws (1), footman loop (2), and strap (4) from body (3) and remove footman loop (2) from
strap (4).
b. Installation
Slide strap (4) onto footman loop (2). Install footman loop (2) and strap (4) on body (3) with two screw (1).
12-269
TM 9-2320-280-20-3
12-177. TRIPOD STRAP REPLACEMENT (L119)

This task covers:
lNITIAL SETUP:
M1097, M1097A1, M1097A2 TM 9-2320-280-10
Tools TM 9-2320-280-24P
automotive (Appendix B, Item 1) Troop seat (R.H.) raised (TM 9-2320-280-10).
a. Removal
1. Remove strap hook (7) from strap buckle (5).

2. Remove four locknuts (4), screws (1), two footman loops (3), and straps (6) from troop seat (2).
b. Installation
1. Slide straps (6) onto two footman loops (3). Install footman loops (3) and straps (6) on troop seat (2)
with four screws (1) and locknuts (4).
2. Attach strap hook (7) on strap buckle (5).
12-270
TM 9-2320-280-20-3
12-178. GUN DISPLAY UNIT BATTERY STRAP REPLACEMENT (L119)

This task covers:
INITIAL SETUP:
One assistant
Tools
TM 9-2320-280-24P
Materials/Parts
Four locknuts (Appendix G, Item 89) Equipment Condition
Left troop seat raised (TM 9-2320-280-10).
NOTE
The G.D.U. battery strap and G.D.U. strap are replaced basically
the same. This procedure covers the G.D.U. battery strap.
a. Removal
1. Remove strap hook (3) from strap buckle (2).

2. Remove two locknuts (7), screws (5), washers (4), footman loop (6), and strap (1) from fixed door (8).
3. Remove two locknuts (9), screws (11), footman loop (10), and strap (1) from fixed door (8). Discard
locknuts (9).
b. Installation
1. Slide strap (1) onto footman loop (6). Install footman loop (6) and strap (1) on fixed door (8) with two
washers (4), screws (5), and locknuts (7).
2. Slide strap (1) onto footman loop (10). Install footman loop (10) and strap (1) on fixed door (8) with
two screws (11) and locknuts (9).
3. Attach strap hook (3) to strap buckle (2).
FOLLOW-ON TASK: Lower left troop seat (TM 9-2320-280-10).
12-271
TM 9-2320-280-20-3
12-179. SIGHT BOX STRAPS REPLACEMENT (L119)

This task covers:
lNITIAL SETUP:
M1097, M1097A1, M1097A2 Six locknuts (Appendix G, Item 89)

NOTE
The sight box #1 straps and the sight box #2 strap are replaced
basically the same. This procedure covers the sight box #1 straps.
a. Removal
1. Remove strap hooks (5) from strap buckles (6).

2. Remove four locknuts (4), screws (1), two footman loops (3), and straps (7) and (16) from ammo
3. Remove two locknuts (10), screws (8), footman loop (9), and strap (7) from ‘C” beam (11). Discard
locknuts (10).
4. Remove two screws (15), washers (14), flat footman loop (13), and strap (16) from cargo floor (12).
Remove strap (16).
b. Installation
1. Slide strap (16) onto flat footman loop (13). Install flat footman loop (13) and strap (16) on cargo
floor (12) with two screws (15) and washers (14).
2. Slide strap (7) onto footman loop (9). Install footman loop (9) and strap (7) on ‘C” beam (11) with two
3. Slide straps (7) and (16) onto two footman loops (3). Install footman loops (3) and straps (7) and (16)
on ammo rack (2) with four screws (1) and locknuts (4).
4. Attach strap hooks (5) on strap buckles (6).
12-272
TM 9-2320-280-20-3
12-180. WATER/FUEL CAN STRAP REPLACEMENT (L119)

This task covers:
INITIAL SETUP:
Materials/Parts
Applicable Models
Personnel Required
One mechanic
One assistant
a. Removal
1. Remove two locknuts (7), washers (6), screws (4), footman loop (5), and strap (3) from footwell (8).
2. Remove strap hook (2) from flat footman loop (1).
b. Installation
1. Slide strap (3) onto footman loop (5). Install footman loop (5) and strap (3) on footwell (8) with two
2. Attach strap hook (2) to flat footman loop (1).
12-273
TM 9-2320-280-20-3
12-181. AMMO RACK MAINTENANCE (L119)

This task covers:
INITIAL SETUP:
One assistant
Tools
TM 9-2320-280-24P
Materials/Parts
Twelve locknuts (Appendix G, Item 89) Equipment Condition

Twelve locknuts (Appendix G, Item 90) Ž Tailgate lowered (TM 9-2320-280-10).
Locknut (Appendix G, Item 58) Ž Troop seat (L.H.) raised (TM 9-2320-280-10).
Four lockwashers (Appendix G, Item 110) Ž Sight box straps removed (para. 12-179).
Ž M60 machine gun straps removed (para. 12-182).
a. Removal
1. Remove twelve locknuts (9), washers (8), capscrews (5), and washers (6) from ammo rack assembly
(3), two plates (7), and wheelhouse (10). Discard locknuts (9).
2. Remove locknut (14), washer (15), capscrew (2), and washer (1) from ammo rack assembly (3) and
"D" beam (16). Discard locknut (14).
3. Remove six capscrews (12) and washers (13) from ammo rack assembly (3) and cargo floor (11).
4. Remove ammo tiedown strap hook (4) from ammo rack assembly (3).
5. Remove ammo rack assembly (3).
12-274
TM 9-2320-280-20-3
12-181. AMMO RACK MAINTENANCE (L119) (Cont’d)

b. Disassembly
1. Remove four locknuts (28), washers (29), screws (18), and two strut spring clips (17) from ammo rack
top tray (21). Discard locknuts (28).
2. Remove eight locknuts (26), washers (27), screws (19), and four spike spring clips (20) from ammo
rack top tray (21). Discard locknuts (26).
3. Remove four capscrews (22), lockwashers (23), washers (24), and ammo rack top tray (21) from
ammo rack (25). Discard lockwashers (23).
c. Assembly
1. Install ammo rack top tray (21) on ammo rack (25) with four washers (24), lockwashers (23), and
capscrews (22).
2. Install four spike spring clips (20) on ammo rack top tray (21) with eight screws (19), washers (27),
and locknuts (26).
3. Install two strut spring clips (17) on ammo rack top tray (21) with four screws (18), washers (29),
and locknuts (28).
12-275
TM 9-2320-280-20-3
12-181. AMMO RACK MAINTENANCE (L119) (Cont’d)

d. Installation
1. Install ammo rack assembly (3) on cargo floor (11) with six washers (13) and capscrews (12).
2. Install ammo rack assembly (3) on “D” beam (16) with washer (1), capscrew (2), washer (15), and
locknut (14).
3. Install ammo rack assembly (3) and two plates (7) on wheelhouse (10) with twelve washers (6),
4. Attach ammo tiedown strap hook (4) to ammo rack assembly (3).
FOLLOW-ON TASKS: Ž Install M60 machine gun straps (para. 12-182).

Ž Install sight box straps (para. 12-179).
Ž Lower troop seat (L. H.) (TM 9-2320-280-10).
Ž Raise tailgate (TM 9-2320-280-10).
12-276
TM 9-2320-280-20-3
12-182. M60 MACHINE GUN STRAP REPLACEMENT (L119)

This task covers:
INITIAL SETUP:
Materials/Parts
Applicable Models
M1097, M1097A1, M1097A2, Two locknuts (Appendix G, Item 89)

a. Removal
1. Remove strap hook (4) from footman loop (3).

2. Remove two locknuts (7), washers (8), screws (2), footman loops (3) and (6), and strap (5) from
ammo rack top tray (1). Remove strap (5) from loop (6). Discard locknuts (7).
b. Installation
1. Install strap (5) on loop (6) and footman loops (3) and (6) on ammo rack top tray (1) with two
2. Attach strap hook (4) to footman loop (3).
12-277
TM 9-2320-280-20-3
12-183. CAMOUFLAGE RACK MAINTENANCE

This task covers:
INITIAL SETUP:
M1097, M1097A1, M1097A2 Twelve locknuts (Appendix G, Item 58)
Tools Eight locknuts (Appendix G, Item 65)
TM 9-2320-280-24P
Personnel Required
One mechanic
One assistant
a. Removal
1. Remove two access covers (17) from windshield (10).

2. Disconnect connector arms (16) from wiper arm pivots (15).
3. Remove four locknuts (7), washers (6), two brackets (9), lower front mounting brackets (5), and
spacers (8) from windshield (10). Discard locknuts (7).
4. Remove two capscrews (12), washers (11), locknuts (2), washers (3), and two rear mounting
brackets (1) and plates (13) from “B” pillar (14). Discard locknuts (2).
5. Remove camouflage rack (4) from vehicle.
12-278
TM 9-2320-280-20-3
12-183. CAMOUFLAGE RACK MAINTENANCE (Cont’d)

b. Disassembly
1. Remove two locknuts (38), washers (37), capscrews (26), washers (27), snubber plates (35),
mounts (34), spacers (30), mounts (29), snubber plates (28), and two lower front mounting
brackets (36) from upper front mounting brackets (31). Discard locknuts (38).
2. Remove four locknuts (42), washers (41), capscrews (33), washers (32), and two upper front
mounting brackets (31) from camouflage rack (4). Discard locknuts (42).
3. Remove two locknuts (47), washers (46), capscrews (19), washers (18), and two rear mounting
brackets (1) from camouflage rack (4). Discard locknuts (47).
4. Remove six locknuts (24), washers (23), capscrews (20), washers (21), three rear footman loops (22),
and three straps (24) from camouflage rack (4). Discard locknuts (24).
5. Remove six locknuts (46), washers (45), capscrews (39), washers (40), three front footman loops (43),
and six washers (44) from camouflage rack (4). Discard locknuts (46).
12-279
TM 9-2320-280-20-3
12-183. CAMOUFLAGE RACK MAINTENANCE (Cont’d)

c. Assembly
1. Install two rear mounting brackets (33) on camouflage rack (9) with two washers (1), capscrews (2),
2. Install two upper front mounting brackets (15) on camouflage rack (9) with four washers (16),
3. Install two snubber plates (12), mounts (13), spacers (14), mounts (18), snubber plates (19), and lower
front mounting brackets (20) on upper front mounting bracket (15) with two washers (11),
4. Install three rear footman loops (5) and three straps (8) on camouflage rack (9) with six washers (4),
5. Install six washers (28) and three front footman loops (27) on camouflage rack (9) with six washers (24),
12-280
TM 9-2320-280-20-3
12-183. CAMOUFLAGE RACK MAINTENANCE
d. Installation
1. Install camouflage rack (9) on vehicle.

2. Install two rear mounting brackets (33) and plates (44) on “B” pillar (45) with two washers (42),
3. Install two brackets (40), lower front mounting brackets (36), and spacers (39) on windshield (41)
with four washers (37) and locknuts (38). Tighten locknuts (38) to 15 lb-ft (20 NŽm).
4. Connect connector arms (47) on wiper arm pivots (46).
5. Install access covers (48) on windshield (41).
12-281
TM 9-2320-280-20-3
Section XI. ACCESSORY KITS INSTALLATION
12-184. ACCESSORY KITS INSTALLATION TASK SUMMARY
TASK PAGE
PROCEDURES
PARA. NO.
12-185. Siren and Warning Light Installation 12-282

12-186. Underbody Protection Kit Replacement 12-296
12-187. Brushguard Assembly Replacement 12-310
12-188. Floor Drain Hole Plate Installation 12-312
1 2 - 1 8 5 . SIREN AND WARNING LIGHT INSTA L L AT I O N

This task covers:
a. Manufactured Items f. Siren Electrical Wires Installation
b. Warning Light Assembly Installation g. Passenger's Side Siren Switch and Driver's Side
c. Siren Assembly Installation Siren Switch Installation
d. Circuit Breaker and Relay Installation h. Warning Light Assembly Electrical Wires
e. Siren and Warning Light Switch and Installation
Indicator Installation i. Siren Battery Wires Installation
INITIAL SETUP:
Material/Parts (Cont'd)
Applicable Models Wire “A” (Appendix D, Fig. 79)
M1025, M1025A1, M1025A2, M1026, M1026A1 Wire “B” (Appendix D, Fig. 80)
Wire “M” (Appendix D, Fig. 81)
Tools Relay Connector (Appendix D, Fig. 82)
General mechanic’s tool kit: Locknut (Appendix G, Item 102)
automotive (Appendix B, Item 1) Two lockwashers (Appendix G, Item 139)
Materials/Parts Ten locknuts (Appendix G, Item 103)
Adhesive (Appendix C, Item 1) Lockwasher (Appendix G, Item 115)
Adhesive-sealant (Appendix C, Item 10) Six lockwashers (Appendix G, Item 125)
Siren mounting bracket (Appendix D, Fig. 68) Lockwasher (Appendix G, Item 127)
Warning light mounting bracket Packing (Appendix G, Item 167)
(Appendix D, Fig. 69) Ten tiedown straps (Appendix G, Item 242)
Wire “D” (Appendix D, Fig. 70)
Wire “F” (Appendix D, Fig. 71) Manual References
Wire “G” (Appendix D, Fig. 72) TM 9-2320-280-24P
Wire “L” (Appendix D, Fig. 73)
Wire “K” (Appendix D, Fig. 74) Equipment Condition
Wire “I” (Appendix D, Fig. 75) • Batteries removed (para. 4-79).
Wire “N” (Appendix D, Fig. 76) • Engine access cover removed (para. 10-15).
Wire “H” (Appendix D, Fig. 77)
Wire “J” (Appendix D, Fig. 78)
a. Manufactured Items
NOT E
Prior to installing the siren and warning light, assemble
required materials listed in “Materials/Parts”.
12-282 Change 1
TM 9-2320-280-20-3
12-185. SIREN AND WARNING LIGHT INSTALLATION (Cont’d)

b. Warning Light Assembly Installation
1. Using fabricated warning light bracket (1) as a template, locate, mark, and drill four
0.343-in. (8.7-mm) diameter holes (5) in left side of roof (7).
2. Locate, mark, and drill 0.750-in. (19.1-mm) diameter hole (6) in left side of roof (7).
3. Cut roof panel insulation (8) away for access to mounting hardware.
4. Install warning light bracket (1) on roof (7) with four washers (3), screws (4), and locknuts (2).
5. Install shell (21), washer (20), and terminal (19) on red lead (22) of warning light assembly (9).
6. Install shell (17), sleeve (16), and terminal (15) on black lead (18) of warning light assembly (9).
7. Install nipple (14) on plate (11).
8. Align studs (10) of warning light assembly (9) to holes in plate (11) and install three washers (12)
and nuts (13).
9. Install warning light assembly (9) on warning light bracket (1).
12-283
TM 9-2320-280-20-3
c. Siren Assembly Installation
1. Using fabricated siren bracket (1) as a template, locate, mark, and drill six 0.343-in. (8.7-mm)
diameter holes (2) in right side of roof (3).
2. Locate, mark, and drill 0.75-in. (19-mm) diameter hole (4) in right side of roof (3).
3. Cut roof panel insulation (5) away for access to mounting hardware.
4. Cut siren lead (28) to a length of 5.0 in. (12.7 cm).
5. Install shell (27), sleeve (26), and terminal (25) on siren lead (28).
6. Install gasket (11), plate (10), and panel (15) on siren bracket (1) with four capscrews (16),
7. Install siren assembly (6) and fabricated ground wire “I” (9) on siren bracket (1) with two
capscrews (16), lockwashers (8), and nuts (7).
8. Install siren bracket assembly (1) on roof (3) with four screws (14), two screws (18), six
9. Connect connector (24) of fabricated wire "H" (23) to siren lead (28) and route wire “H” (23) and
ground wire "I" (9) through hole (4).
10. Split grommet (20) and install grommet (20) in hole (4).
11. Install siren wires (23) and (9) on siren bracket (1) with clamp (19), washer (22), screw (21), and
nut (17).
12-284
TM 9-2320-280-20-3
d. Circuit Breaker and Relay Installation
1. Locate, mark, and drill two 0.187-in. (4.8-mm) diameter holes (2) in battery box panel (1).
2. Install circuit breaker (5) on battery box panel (1) with two screws (6), lockwashers (3), and nuts (4).
3. Locate, mark and drill two 0.281-in (7.1-mm) diameter holes (7) in body side panel (8).
NOTE
Note location of external-tooth lockwashers to top relay mounting
screw when installing wires "I", "J", and "K" to relay mounting ground.
4. Install relay (18) on body side panel (8) with two washers (17), screws (19), lockwashers (20), and
nuts (16). Finger tighten top nut (16).
5. Cut lead 467(A) (9) from main light switch connector (21) and install two shells (10),
sleeves (11), and terminals (12) on ends of cut leads 467(A) (9).
6. Connect adapter connector “C” (15) to two leads 467(A) (9).
7. Connect relay connector (14) to relay (18).
8. Connect relay lead “A” (13) to adapter “C” (15).
12-285
TM 9-2320-280-20-3

e. Siren and Warning Light Switch and Indication Installation
1. Loosen nut (1) and lower steering column (2).

2. Locate, mark, and drill six 0.187-in. (4.8-mm) diameter holes (3) in dash panel (5).
3. Locate, mark, and drill three 0.750-in. (19-mm) diameter holes (4) in dash panel (5).
4. Install warning light switch (11) on dash panel (5) with two lockwashers (10) and screws (9).
5. Install lamp (13) on indicator lamp assembly (12) and install indicator lamp assembly (12) on dash
panel (5) with two screws (6).
6. Install packing (8) and lens (7) on dash panel (5).
12-286
TM 9-2320-280-20-3
f. Siren and Electrical Wires Installation
1. Locate, mark, and drill 0.625-in. (15.9-mm) diameter hole (1) in left side of dash panel (2).
2. Route siren wires "H" (4) and “I” (5) along top, and down left side, of windshield frame (3).
3. Route siren wires “H” (4) "I" (5) through hole (1) in left side of dash panel (2).
4. Split grommet (6) and install grommet (6) in hole (1).
5. Connect siren wire "H" (4) to adapter connector “E” (7).
6. Remove top nut (8) and lockwasher (11) from relay (9) and install siren wire "I" (5) on top mounting
screw (10) of relay (9).
12-287
TM 9-2320-280-20-3

g. Passenger's Side Siren Switch and Driver's Side Siren Switch Installation
1. Install two shells (3), washers (4), and terminals (5) on leads (2) of passenger’s side siren switch (1).
2. Tape and secure two unused leads (6) of passenger’s siren switch (1).
NOTE
Passenger’s side and driver’s side siren switch are the same.
Repeat steps 1 and 2 for driver’s side switch.
3. Locate, mark, and drill two 0.187-in. (4.8-mm) diameter holes (8) and 0.750-in. (19-mm) diameter
hole (7) on “A” beam (9).
4. Install passenger’s side siren switch (1) on “A” beam (9) with two lockwashers 10) and screws (11).
12-288
TM 9-2320-280-20-3

5. Install driver’s side siren switch (15) on dash panel (14) with two lockwashers (12) and screws (13).
6. Route fabricated wire “G” (17) along tunnel (27) and connect connector (24) to lead (22) of
passenger’s side siren switch.
7. On driver’s side, connect wire “G” (17) connector (30) to adapter connector “E” (28).
8. Connect lead (29) of driver’s side siren switch (15) to adapter connector “E” (28).
9. Connect lead (31) of driver’s side siren switch (15) to adapter connector “B” (32).
10. On driver’s side, connect one end of fabricated wire “D” (33) to adapter “B” (32), and the other end to
adapter connector “A” (34).
11. On driver’s side, connect lead “B” (35) of relay (36) to adapter “A” (34).
12. Route fabricated wire “F" (16) along tunnel (27), and connect connector (25) to lead (23) of
passenger’s side siren switch (21).
13. On driver’s side, connect wire "F" (16) to adapter connector “B” (32).
14. Locate, mark, and drill three 0.146-in. (3.7-mm) diameter holes (20) in right side engine panel (19)
and vehicle tunnel (27).
15. Install wires "F" (16) and “G” (17) on panel (19) with clamp (26) and screw (18).
16. Install wires “F” (16) and “G” (17) on tunnel (27) with five clamps (26) and screws (18).
17. Tuck exposed wires under vehicle insulation on tunnel (27).
12-289
TM 9-2320-280-20-3
h. Warning Light Assembly Electrical Wires Installation
1. Install and connect fabricated wire "M" (11) to red lead (10), and wire “J” (1) to black lead (2) of
warning light assembly (3).
2. Install fabricated wires “M” (11) and “J” (1) on bracket (4) with clamp (5), washer (7), screw (6), and
locknut (8).
3. Route fabricated wires "M" (11) and “J” (1) in roof (9).
4. Route fabricated wires "M" (11) and “J” (1) downward along windshield frame (12).
12-290
TM 9-2320-280-20-3
12-185. SIREN AND WARNING LIGHT lNSTALLATION (Cont’d)

5. Route fabricated wires "M" (11) and "J" (1) through grommet (14) and hole in left side dash panel (13).
6. Connect fabricated wire “M” (11) to adapter (15).
7. Install fabricated wire "J" (1) on top mounting screw (23) of relay (22).
8. Connect indicator light lead (17) to adapter “D” (15).
9. Connect fabricated wire “A” (16) to adapter “D” (15) and connector (19) to light switch (20).
10. Connect fabricated wire "B" (18) to adapter “A” (21) and warning light switch (20).
11. Split grommet (24) and install grommet (24) on roof (9). Apply adhesive-sealant RTV on
grommet (24).
12-291
TM 9-2320-280-20-3

i. Siren Battery Wires Installation
1. Install fabricated wire "K" (1) on top mounting screw (6) of relay (5) with washer (7) and nut (2).
2. Install fabricated wire “L” (3) on lead “C” (4) of relay (5).
3. Route wires “K” (1) and “L” (3) through grommet opening (8) in firewall (9).
4. Route wires (10) along cable harness (11) in engine compartment (12).
5. Raise steering column (14) and tighten nut (13).
12-292
TM 9-2320-280-20-3

6. Route wire "L" (3) through grommet (16) in battery box (15).
7. Connect wire "L" (3) to circuit breaker (25).
8. Remove nut (19) and lockwasher (20) from ground stud (18). Discard lockwasher (20). Connect
fabricated wire “K” (1) to ground stud (18) on vehicle body (17) and install wire “K” (1) with
lockwasher (20) and nut (19).
9. Remove nut (24) and lockwasher (23) from positive power stud (21). Discard lockwasher (23).
Connect fabricated wire "N" (22) to circuit breaker (25) and power stud (21). Install wire “N” (22) on
stud (21) with lockwasher (23) and nut (24).
12-293
TM 9-2320-280-20-3

10. Locate, mark, and drill two 0.146-in. (3.7-mm) diameter holes (6), equally spaced, in left side
windshield frame (8) and four 0.146-in. (3.7-mm) diameter holes (5), equally spaced, along top of
windshield frame (3).
11. Install wires (4) and warning light wires (9) on left side windshield frame (8) and along top of
windshield frame (3) with six clamps (2) and screws (1).
12. Install warning light wires (9) on wiring harness under dash (7) and engine compartment (10) with
ten tiedown straps (11).
13. Apply adhesive to right and left side roof panel insulation (12), and install on roof (13).
12-294
TM 9-2320-280-20-3
1 2 - 1 8 5 . SIREN AND WARNING LIGHT INSTA L L ATION (Cont'd)

• Install batteries (para. 4-79).
• Check siren and warning light for proper operation.
Change 1 12-295
TM 9-2320-280-20-3
1 2 - 1 8 6 . UNDERBODY PROTECTION KIT REPLACEMENT

This task covers:
a. Front Skid Plate Removal g. Fuel Tank Shield Installation
b. Front Shield Removal h. Rear Shield Installation
c. Intermediate Shield Removal i. Transfer Case Shield Installation
d. Transfer Case Shield Removal j. Intermediate Shield Installation
e. Rear Shield Removal k. Front Shield Installation
f. Fuel Tank Shield Removal l. Front Skid Plate Installation
INITIAL SETUP:
M997A2, M1025A2, M1035A2, M1043A2, TM 9-2320-280-10
M1045A2, M1097A2, M1123 TM 9-2320-280-24P
General mechanic’s tool kit: automotive • Do not perform this procedure near fire, flames
(Appendix B, Item 1) or sparks.
• Fuel tank must be supported during removal
Materials/Parts and installation.
Four rubber washers (Appendix G, Item 204.1)
Forty-six locknuts (Appendix G, Item 106)
a. Front Skid Plate Removal
1. Remove three locknuts (9), six washers (2), three capscrews (7), and front skid plate (6) from front
2. Remove three locknuts (5), six washers (3), three capscrews (4), and front skid plate (6) from front
bumper (1). Discard locknuts (5).
12-296 Change 1
TM 9-2320-280-20-3
1 2 - 1 8 6 . UNDERBODY PROTECTION KIT REPLACEMENT (Co n t ’ d )
b. Front Shield Removal
1. Remove three locknuts (16), six washers (17), and three capscrews (18) from front shield (14), front
crossmember (15), and intermediate shield (19). Discard locknuts (16).
2. Remove three locknuts (13), six washers (12), three capscrews (11), and front shield (14) from front
skid plate (10). Discard locknuts (13).
Change 1 12-297
TM 9-2320-280-20-3
c. Intermediate Shield Removal
1. Remove six locknuts (6), twelve washers (2), six capscrews (3), four rubber washers (5), and two
transmission support brackets (4) from intermediate shield (1) and transmission mount cross-
member (7). Discard locknuts (6) and rubber washers (5).
2. Remove locknut (8), two washers (9), and capscrew (10) from right support bracket (15) and right
side frame rail (16). Discard locknut (8).
3. Remove locknut (22), two washers (19), and capscrew (18) from left support bracket (24), engine
mount bracket (17), and left side frame rail (23). Discard locknut (22).
4. Remove four locknuts (14), eight washers (12), four capscrews (11), and right side support
bracket (15) from right side mounting bracket (13). Discard locknuts (14).
5. Remove four locknuts (26), eight washers (21), four capscrews (20), and left side support bracket (24)
from left side mounting bracket (25). Discard locknuts (26).
6. Remove two locknuts (29), four washers (30), two capscrews (31), and intermediate shield (1) from
front crossmember (27) and front shield (28). Discard locknuts (29).
12-298 Change 1
TM 9-2320-280-20-3
Change 1 12-299
TM 9-2320-280-20-3
d. Transfer Case Shield Removal
Remove two locknuts (1), four washers (2), two capscrews (4), and transfer case shield (5) from cross-
member (3). Discard locknuts (1).
12-300 Change 1
TM 9-2320-280-20-3
e. Rear Shield Removal
1. Remove three locknuts (18), six washers (16), three capscrews (15), and spacers (17) from rear
shield (19) and rear-front crossmember (14). Discard locknuts (18).
2. Remove three locknuts (10), six washers (11), three capscrews (13), and rear shield (19) from three
mounting brackets (12). Discard locknuts (19).
3. Remove six locknuts (9), twelve washers (7), six capscrews (6), spacers (20), and three mounting
brackets (12) from rear-rear crossmember (8). Discard locknuts (9).
Change 1 12-301
TM 9-2320-280-20-3
f. Fuel Tank Shield Removal
.WARNING.
• Fuel tank must be supported during removal and installation;
failure to do so may cause damage to fuel tank or injury to
personnel.
• Diesel fuel is highly flammable. Do not perform this task near
fire, flames, or sparks. Severe injury or death may result.
1. Drain fuel tank (1) (refer to para. 3-24).
2. Remove two locknuts (6), four washers (2), two capscrews (3), and support straps (5) from upper
straps (4). Discard locknuts (6).
3. Swing support straps (5) down and remove fuel tank shield (7).
g. Fuel Tank Shield Installation
.WARNING.
• Fuel tank must be supported during removal and installation;
failure to do so may cause damage to fuel tank or injury to
personnel.
• Diesel fuel is highly flammable. Do not perform this task near
fire, flames, or sparks. Severe injury or death may result.
1. Position fuel tank shield (7) on fuel tank (1) and raise support straps (5).
NOTE
Maintain 0.50 in. (13mm) clearance between upper and lower
straps when tightening locknuts.
2. Install support straps (5) to upper straps (4) with two capscrews (3), four washers (2), and two
3. Fill fuel tank (1) (refer to TM 9-2320-280-10).
12-302 Change 1
TM 9-2320-280-20-3
0.50 in.
(13 mm)
Change 1 12-303
TM 9-2320-280-20-3
h. Rear Shield Installation
1. Install rear shield (14) to rear-front crossmember (9) with three spacers (12), capscrews (10), six
washers (11), and three locknuts (13). Tighten locknuts (13) to 44 lb-ft (60 N•m).
2. Install rear shield (14) on three mounting brackets (7) with three capscrews (8), six washers (6), and
three locknuts (5). Do not tighten locknuts (5).
3. Install three mounting brackets (7) on rear-rear crossmember (3) with six spacers (15), capscrews (1),
twelve washers (2), and six locknuts (4). Tighten locknuts (4) to 24 lb-ft (33 N•m).
4. Tighten three locknuts (5) to 24 lb-ft (33 N•m).
12-304 Change 1
TM 9-2320-280-20-3
i. Transfer Case Shield Installation
Install transfer case shield (20) on crossmember (18) with two capscrews (19), four washers (17), and two
locknuts (16).
Change 1 12-305
TM 9-2320-280-20-3
j. Intermediate Shield Installation
1. Install intermediate shield (6) and front shield (2) on front crossmember (1) with four washers (4),
two capscrews (5), and locknuts (3). Tighten locknuts (3) to 44 lb-ft (60 N•m).
2. Install left side support bracket (14) on left side mounting bracket (15) with eight washers (11), four
capscrews (10), and locknuts (16). Do not tighten locknuts (16).
3. Install right side support bracket (24) on right side mounting bracket (22) with eight washers (21),
four capscrews (20), and locknuts (23). Do not tighten locknuts (23).
4. Install left side support bracket (14) on engine mount bracket (7) and left side frame rail (13) with
two washers (9), capscrew (8), and locknut (12). Tighten locknut (12) to 105 lb-ft (142 N•m).
5. Install right side support bracket (24) on right side frame rail (25) with two washers (18), capscrew (19),
and locknut (17). Tighten locknut (17) to 105 lb-ft (142 N•m).
6. Install two transmission support brackets (28) on intermediate shield (6) and transmission mount
crossmember (31) with twelve washers (26), four rubber washers (29), six capscrews (27), and
locknuts (30). Tighten locknuts (30) to 30 lb-in. (3 N•m).
12-306 Change 1
TM 9-2320-280-20-3
Change 1 12-307
TM 9-2320-280-20-3
k. Front Shield Installation
1. Install front shield (5) on front skid plate (1) with six washers (3), three capscrews (2), and
2. Install front shield (5) on front crossmember (6) and intermediate shield (9) with six washers (8),
three capscrews (10), and locknuts (7).
12-308 Change 1
TM 9-2320-280-20-3
l. Front Skid Plate Installation
1. Install front skid plate (16) on front bumper (11) with six washers (13), three capscrews (14), and
2. Install front skid plate (16) on front shield (18) with six washers (12), three capscrews (17), and
Change 1 12-309
TM 9-2320-280-20-3
1 2 - 1 8 7 . BRUSHGUARD ASSEMBLY REPLACEMENT
This task covers:

a. Brushguard Assembly Replacement d. Quick-Release Brace Replacement
b. Tube Assembly Replacement e. Landyard Replacement
c. Pivot Brace Replacement
INITIAL SETUP:
M997A2, M1025A2, M1035A2, M1043A2, TM 9-2320-280-24P
M1045A2, M1097A2, M1123
Tools
a. Brushguard Assembly Replacement

1. Remove two nuts (15), washers (16), capscrews (20), and washers (16) from pivot brace (13).
2. Remove two pins (18) from brushguard assembly (4) and quick-release brace (19) and remove
brushguard assembly (4) from pivot brace (13).
3. Position brushguard assembly (4) on pivot brace (13) and install two pins (18) through brushguard
assembly (4) on quick-release brace (19).
4. Install two washers (16), capscrews (20), washers (16), and nuts (15) on pivot brace (13).
b. Tube Assembly Replacement

NOTE
Perform these steps for three-piece brushguard only.
1. Remove two nuts (22), washers (2), capscrews (3), washers (2), and tube assembly (1) from
brushguard assembly (4). Repeat step for other side.
2. Install tube assembly (1) on brushguard assembly (4) with two washers (2), capscrews (3),
washers (2), and nuts (22). Repeat step for other side.
c. Pivot Brace Replacement
1. Remove brushguard assembly (4) (task a).
2. Remove two nuts (11), washers (12), capscrews (14), washers (12), and pivot brace (13) from
bumper (8).
3. Install pivot brace (13) on bumper (8) with two washers (12), capscrews (14), washers (12), and nuts (11).
4. Install brushguard assembly (4) (task a).
d. Quick-Release Brace Replacement
1. Remove two pins (18) from brushguard assembly (4) and quick-release brace (13) and lower brush-
guard assembly (4).
NOTE
Vehicles equipped with winch will not have nuts and washers as
indicated in steps 2 and 3.
2. Remove two nuts (9), washers (10), capscrews (17), washers (10), and brace (19) from bumper (8).
3. Install brace (19) on bumper (8) with two washers (10), capscrews (17), washers (10), and nuts (9).
4. Raise brushguard assembly (4) and install two pins (18) through brushguard assembly (4) and brace (19).
12-310 Change 1
TM 9-2320-280-20-3
1 2 - 1 8 7 . BRUSHGUARD ASSEMBLY REPLACEMENT (Cont’d)
e. Landyard Replacement
1. Remove nut (21), screw (7), washer (6), landyard (5), and pin (18) from brushguard assembly (4).
Repeat step for other side.
2. Install pin (18) and landyard (5) on brushguard assembly (4) with washer (6), screw (7), and nut (21).
Repeat step for other side.
Change 1 12-311
TM 9-2320-280-20-3
1 2 - 1 8 8 . FLOOR DRAIN HOLE PLATE INSTALLATION

This task covers:
Installation
INITIAL SETUP:
automotive (Appendix B, Item 1) TM 43-0139
Materials/Parts
Adhesive sealant (Appendix C, Item 2.1)
Installation
NOT E
All drain hole plates are installed basically the same. This
procedure covers one drain hole plate.
1. Mark on outline at drain hole (3) on floor panel (4).

2. Cut and remove drain hole material (1) from floor panel (4), and remove sharp edges and burrs from
floor panel (4).
3. Mark underside of floor panel (4) with two lines centered over damaged floor drain area.
4. Using a 0.187-inch diameter drill, remove rivet (2) securing floor panel (4) to side body panel (6).
NOT E
• It may be necessary to bend or shape the drain hole plate to the
contour of the floor panel.
• When installed, the drain hole plate opening faces toward the
center of the vehicle.
5. Position drain hole plate (5) to underside of floor panel (4). Bend or shape drain hole plate (5) to the
contour of the floor panel (4).
6. Using drain hole plate (5) as a template, locate, mark, and drill seven 0.187-in (4.8 mm) diameter
holes on floor panel (4).
7. Apply approximately 0.125 in. (3.175 mm) thickness of adhesive sealant to shaded mating surface on
drain hole plate (5).
8. Apply approximately 0.125 in. (3.175 mm) thickness of adhesive sealant to shaded mating surface on
underside of floor panel (4) and side body panel (6).
9. Position drain hole plate (5) to underside of floor panel (4) and install seven rivets (2) on floor
panel (4) and drain hole plate (5).
10. Using rivet hole drilled in step 4 as a template, drill 0.187-in. diamter hole through drain hole
plate (5).
11. Install rivet (2) on floor panel (4), side body panel (6), and drain hole plate (5).
12. Remove adhesive and clean edges on floor panel (4) and drain hole plate (5).
13. Spot paint floor panel (4) and drain hole plate (5) (TM 43-0139).
12-312 Change 1
TM 9-2320-280-20-3
1 2 - 1 8 8 . FLOOR DRAIN HOLE PLATE INSTA L L ATION (Contd)
FRONT OF VEHICLE
Change 1 12-313
TM 9-2320-280-20-3
Section XII. CARGO BARRIER AND NET KIT MAINTENANCE
12-189. CARGO BARRIER AND NET KIT MAINTENANCE TASK SUMMARY
TASK PAGE
PROCEDURES
PARA. NO.
12-190. Cargo Barrier Channel Replacement 12-314

12-191. Antiskid Strip Replacement 12-316
1 2 - 1 9 0 . CARGO BARRIER CHANNEL REPLACEMENT

This task covers:
INITIAL SETUP:
M1025, M1025A1, M1026, M1026A1 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
General mechanics’s tool kit: Equipment Condition
automotive (Appendix B, Item 1) Cargo barrier and net removed (TM 9-2320-280-10).
NOT E
Replacement procedure for left and right cargo barrier channels are
the same. This procedure covers the left cargo barrier channel.
a. Removal
Remove two nuts (2), washers (3), screws (5), and channel (4) from armor plate (6) and wheelhouse (1).
b. Installation
Install channel (4) on armor plate (6) and wheelhouse (1) with two screws (5), washers (3), and nuts (2).
12-314 Change 1
TM 9-2320-280-20-3
1 2 - 1 9 0 . CARGO BARRIER CHANNEL REPLACEMENT (Cont’d)
FOLLOW-ON TASK: Install cargo barrier and net (TM 9-2320-280-10).
Change 1 12-315
TM 9-2320-280-20-3
1 2 - 1 9 1 . ANTISKID STRIP REPLACEMENT

This task covers:
INITIAL SETUP:
M1025, M1025A1, M1026, M1026A1 TM 9-2320-280-10
TM 9-2320-280-24P
Tools
automotive (Appendix B, Item 1) Stowage compartment net removed
(TM 9-2320-280-10).
a. Removal
1. Remove antiskid strip (4) from cargo floor (3).

2. Clean remaining adhesive from cargo floor (3).
3. Inspect plugs (1) in cargo floor (3) and right wheelhouse (2), and replace plugs (1) if damaged.
b. Installation
1. Ensure surface of cargo floor (3) is free of dirt and oil.

2. Peel paper backing (5) from antiskid strip (4) and press antiskid strip (4) firmly onto cargo floor (3).
12-316 Change 1
TM 9-2320-280-20-3
1 2 - 1 9 1 . ANTISKID STRIP REPLACEMENT (Cont’d)
FOLLOW-ON TASK: Install stowage compartment net (TM 9-2320-280-10).
Change 1 12-317/(12-318 blank)

TM 9-2320-280-20-3
CHAPTER 13
PREPARATION FOR STORAGE OR SHIPMENT
Section I. GENERAL INSTRUCTIONS
13-1. SCOPE
a. This chapter describes requirements for preparation of M998 series vehicles and components for
shipment and limited storage.
b. When vehicles are shipped or stored, the officer in charge is responsible for preparing the vehicles in a
properly maintained and serviceable condition. Vehicles must be properly cleaned, preserved, painted, and
lubricated. Vehicles, componentry, and BII must be prepared and protected to prevent corrosion,
deterioration, and physical damage.
13-2. ADMINISTRATIVE STORAGE
a. Administrative storage is the placement of a unit’s organic material in a limited care and preservation
status for shoft periods of time.
b. Instructions and requirements pertaining to administrative storage are found in DA PAM 738-750.
13-3. SECURITY
a. Equipment and vehicle security requirements are covered in AR 190-13 and AR 190-51.
b. Cryptographic materials or COMSEC equipment will not be shipped with vehicles or remain in vehicles
in storage. Refer to (C)AR 380-40 for information concerning COMSEC materials.
c. Access to materiel in storage should be strictly controlled to prevent unauthorized cannibalization or
pilferage. Refer to AR 750-1.
13-4. SPECIAL PACKAGING AND SHIPPING REQUIREMENTS
a. When required, wrap, pack, mark, and stow uninstalled government furnished equipment and BII in
accordance with MIL-B-12841, MIL-STD-129, MIL-V-62038, and TM 746-10.
b. Height and width of vehicles prepared for rail transportation must not exceed the limitations of
AR 700-15. Whenever possible, local transportation personnel must be consulted about limitations of
particular railroad lines to be used for movement in order to avoid delays, dangerous conditions, or damage
to equipment.
c. Loading and blocking procedures must be in accordance with pamphlet no. MD-7, Rules Governing the
Loading of Defense Material on Open-Top Cars, of Association of American Railroads.
d. Loading and blocking of vehicles for highway shipment must be in accordance with Interstate
Commerce Commission Publication “Motor Carrier Safety Regulations.”
e. For specific instructions concerning loading and blocking of M998 series vehicles for air, land, or sea
shipment, refer to TM 55-2320-280-14.
13-1
TM 9-2320-280-20-3
Section Il. PREPARATION FOR STORAGE AND SHIPMENT
13-5. GENERAL STORAGE AND SHIPPING INFORMATION
a. Storage procedures will be such that the vehicle can be returned to service and operated with
minimum delay. Disassembly should be limited to that necessary to clean and preserve exposed
surfaces and equipment and to the maximum extent consistent with safe storage. The vehicle will be
placed in storage in as nearly a completely assembled condition as practical.
b. Storage site selection should offer maximum protection from the environment and provide access for
inspection, maintenance, and vehicle exercise if necessary.
c. For long term storage refer to MIL-V-62038 for information concerning preparation of vehicles and
components.
13-6. CLEANING
a. Before applying preservatives, thoroughly clean all vehicle surfaces of corrosion, soil, grease,
damaged paint, or other foreign materials. Refer to TM 9-2320-280-10 for M998 series vehicles cleaning
instructions.
WARNING
● Drycleaning solvent is flammable and will not be used near an
open flame. A fire extinguisher will be kept nearby when the
solvent is used. Use only in well-ventilated places. Failure to do
this may result in injury to personnel and/or damage to
equipment.
Protective gloves, clothing, and/or respiratory equipment must
be worn whenever caustic, toxic, or flammable cleaning
solutions are used. Failure to do this may result in injury to
personnel and/or damage to equipment.
CAUTION
● Do not allow cleaning compounds to come into contact with
rubber, leather, vinyl, or canvas materials. Damage to
equipment will result.
● Do not use compressed air when cleaning vehicle interiors.
Damage to equipment can result.
b. Descriptions and uses of cleaning compounds, solvents, drycleaning solutions, and corrosion removing
compounds are found in TM 9-247. Refer to TM 9-2320-280-10 as a general guide of cleaning materials used
in removing contaminants from M998 series vehicles.
13-7. INSPECTIONS, STOWAGE, AND INVENTORY
a. Perform a semiannual (S) PMCS on vehicles intended for limited storage or shipment. (See table 2-1
in chapter 2.)
b. Apply all urgent MWO’s to vehicle and equipment (DA PAM 25-30).
C. Inventory the vehicle and components (TM 9-2320-280-10-HR) and ensure proper stowage of
components and BII (TM 9-2320-280-10).
d. Prepare uninstalled BII and government furnished equipment in accordance with para. 13-4a.
13-2
TM 9-2320-280-20-3
13-8. REPAIR, PAINTING, AND PRESERVATION
a. All equipment deficiencies noted during inspections should be repaired in accordance with vehicle TM’s.
b. All unpainted metal surfaces must be protected during storage or shipment. Inspect, clean, and spot
paint metal surfaces as required in TM 9-2320-280-10. Unpainted exposed machined surfaces must be
prepared with corrosion-preventive compounds or oil and grease as referenced in TM 9-2320-280-10. Be sure
to select preservatives that will not harm vehicle interior components.
c. Sunlight, heat, moisture, and dirt accelerate deterioration. Install all covers authorized for the
equipment. Close and secure all openings except those required for venting and drainage. Seal all openings
to prevent the entry of rain, snow, or dust.
d. Inflate tires to a maximum of 30 psi (207 kPa).
13-9. LUBRICATION
Lubricate vehicles in accordance with TM 9-2320-280-10 and TM 9-2320-280-20-1 before shipment or storage.
13-10. RECORDS AND REPORTS
Maintenance records required by AR 750-1 will be maintained and reports submitted in accordance with DA
PAM 738-750 and AR 220-1.
13-3/(13-4 blank)
TM 9-2320-280-20-3
APPENDIX A
REFERENCES
A-1. SCOPE
This appendix lists all forms, field manuals, technical manuals, and other publications required for use
with this manual.
A-2. PUBLICATIONS INDEX

The following index should be consulted frequently for latest changes or revisions and for new publications
relating to materiel covered in this manual.
Consolidated Index of Army Publications and Blank Forms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA PAM 25-30
A-3. FORMS
Recommended Changes to Publications and Blank Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2028
Recommended Changes to Equipment Technical Publications. . . . . . . . . . . . . . . . . . . . . . . . DA Form 2028-2
Hand Receipt/Annex Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2062
Exchange Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2402
Equipment Inspection and Maintenance Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2404
Maintenance Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA Form 2407
The Army Maintenance Management System (TAMMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DA PAM 738-750
Preventive Maintenance Schedule and Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DD Form 314
Processing and Deprocessing Record for Shipping, Storage,
and Issue of Vehicles and Spare Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DD Form 1397
A-4. FIELD MANUALS

NBC Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 3-4
NBC Decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 3-5
Operation and Maintenance of Ordnance Materiel in Cold Weather (0° to -65°F) . . . . . . . . . . . . FM 9-207
First Aid for Soldiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 21-11
Manual for the Wheeled Vehicle Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 21-305
Browning Machinegun Caliber .50 HB, M2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 23-65
Machinegun 7.62-MM, M60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 23-67
Basic Cold Weather Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 31-70
Northern Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 31-71
Army Motor Transport Units and Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 55-30
Mountain Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 90-6
A-5. TECHNICAL MANUALS

Inspection, Care and Maintenance of Antifriction Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-214
Solder and Soldering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB-SIG-222
Materials Used for Cleaning, Preserving, Abrading, and Cementing Ordnance
Materiel and Related Materials (Including Chemicals) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-247
Operator's Manual for Machinegun, Caliber .50 Browning, M2. . . . . . . . . . . . . . . . . . . . . . . TM 9-1006-224-10
Operator's Manual for M60, 7.62-MM Machinegun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-1006-224-10
A-1
TM 9-2320-280-20-3
A-5. TECHNICAL MANUALS (Cont'd)

Operator's and Organizational Maintenance Manual for
TOW 2 Weapon System, Guided Missile System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-1425-450-12
Operator's and Organizational Maintenance Manual for
TOW Weapon System, Guided Missile System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-1425-472-12
Operator's Manual for Truck, 1-1/4 Ton, 4X4, M998 Series . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2320-280-10
Unit, Direct Support and General Support Maintenance Repair Parts and
Special Tools List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2320-280-24P
Operator’s, Unit, Direct Support and General Support Maintenance Manual For
Care, Maintenance, Repair and Inspection of Pneumatic Tires,
Inner Tubes, and Radial Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2610-200-14
Operator’s, Organizational, Direct Support and
General Support Maintenance Manual for Lead-Acid Storage Batteries . . . . . . . . . . TM 9-6140-200-14
Marking, Packaging and Supplies and Equipment:
General Packaging Instructions for Field Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 746-10
Procedures for Destruction of Tank Automotive Equipment to Prevent Enemy Use . . . . . . TM 750-244-6
Cooling Systems: Tactical Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 750-254
Principles of Automotive Vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-8000
Painting Instructions for Army Materiel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 43-0139
A-6. TECHNICAL BULLETINS

Tactical Wheeled Vehicles: Repair of Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2300-241-40
Security of Tactical Wheeled Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 9-2300-422-20
Equipment Improvement Report and Maintenance Digest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 43-0001-39
Use of Antifreeze Solutions and Cleaning Compounds
in Engine Cooling Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 750-651
Corrosion Prevention and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 43-0213
A-7. ARMY REGULATIONS

Identification and Distribution of DA Publications and Issue of
Agency and Command Administrative Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 310-2
Dictionary of United States Army Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 310-25
A-8. OTHER PUBLICATIONS

Army Acquisition Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 70-1
The Army Physical Security Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 190-13
Security of Unclassified Army Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 190-51
Unit Status Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 220-1
Policy for Safeguarding and Controlling Comsec Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 380-40
Prevention of Motor Vehicle Accidents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 385-55
Packaging of Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR 700-15
Army Material Maintenance Policy and Retail Maintenance Operation . . . . . . . . . . . . . . . . . . . . . . . . AR 750-1
Expendable/Durable Items (Except: Medical, Class V, Repair Parts and Heraldic Items). . . . . . . . . CTA 50-970
Hand Receipt for Truck, 1-1/4 Ton, 4X4, M998 Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 9-2320-280-10 HR
Transportability Guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM 55-2320-280-14
A-2 Change 1
TM 9-2320-280-20-3
APPENDIX B
MAINTENANCE ALLOCATION CHART
Section I. INTRODUCTION
B-1. THE ARMY MAINTENANCE SYSTEM (MAC)
a. This section provides a general explanation of all maintenance and repair functions authorized at
various maintenance levels under the standard Army Maintenance System Concept.
b. The Maintenance Allocation Chart (MAC) in section II designates overall authority and responsibility
for the performance of maintenance functions on the identified end item or component. The application of
the maintenance functions to the end item or component will be consistent with the capacities and
capabilities of the designated maintenance levels, which are shown on the MAC in column (4) as:
Unit - includes two subcolumns, C (operator/crew ) and O
(unit) maintenance.
Direct Support - includes an F subcolumn.
General Support - includes an H subcolumn.
Depot - includes a D subcolumn.
c. Section III lists the tools and test equipment (both special tools and common tool sets) required for each
maintenance function as referenced from section II.
d. Section IV contains supplemental instructions and explanatory notes for a particular maintenance function.
B-2. MAINTENANCE FUNCTIONS
Maintenance functions will be limited to and defined as follows:

a. Inspect. To determine the serviceability of an item by comparing its physical, mechanical, and/or
electrical characteristics with established standards through examination (e.g., by sight, sound, or feel).
b. Test. To verify serviceability by measuring the mechanical, pneumatic, hydraulic, or electrical
characteristics of an item and comparing those characteristics with prescribed standards.
c. Service. Operations required periodically to keep an item in proper operating condition, i.e., to clean
(includes decontaminate, when required), to preserve, to drain, to paint, or to replenish fuel, lubricants,
chemical fluids, or gases.
d. Adjust. To maintain or regulate, within prescribed limits, by bringing into proper or exact position, or
by setting the operating characteristics to specified parameters.
e. Align. To adjust specified variable elements of an item to bring about optimum or desired performance.
f. Calibrate. To determine and cause corrections to be made or to be adjusted on instruments or test,
measuring, and diagnostic equipment used in precision measurement. Consists of comparisons of two
instruments, one of which is a certified standard of known accuracy, to detect and adjust any discrepancy in
the accuracy of the instrument being compared.
g. Remove/Install. To remove and install the same item when required to perform service or other
maintenance functions. Install maybe the act of emplacing, seating, or fixing into position a spare, repair
part, or module (component or assembly) in a manner to allow the proper functioning of an equipment or
system.
h. Replace. To remove an unserviceable item and install a serviceable counterpart in its place. "Replace"
is authorized by the MAC and is shown as the 3d position code of the SMR code.
B-1
TM 9-2320-280-20-3
i. Repair. The application of maintenance services, including fault location/troubleshooting,

removal/installation, and disassembly/assembly procedures, and maintenance actions to identify troubles
and restore serviceability to an item by correcting specific damage, fault, malfunction, or failure in a part,
subassembly, module (component or assembly), end item, or system.
j. Overhaul. That maintenance effort (service/action) prescribed to restore an item to a completely
serviceable/operational condition as required by maintenance standards in appropriate technical
publications (i.e., DMWR). Overhaul is normally the highest degree of maintenance performed by the Army.
Overhaul does not normally return an item to like-new condition.
k. Rebuild. Consists of those services/actions necessary for the restoration of unserviceable equipment to
a like-new condition in accordance with original manufacturing standards. Rebuild is the highest degree of
materiel maintenance applied to Army equipment. The rebuild operation includes the act of returning to
zero those age measurements (hours/ miles, etc.) considered in classifying Army equipment/components.
B-3. EXPLANATION OF COLUMNS IN THE MAC, SECTION II
a. Column (1)-Group Number. Column 1 lists functional group code numbers, the purpose of which is
to identify maintenance significant components, assemblies, subassemblies, and modules with the next
higher assembly.
b. Column (2)-Component/Assembly. Column 2 contains the names of components, assemblies,
subassemblies, and modules for which maintenance is authorized.
c. Column (3)-Maintenance Function. Column 3 lists the functions to be performed on the item
listed in Column 2. (For detailed explanation of these functions, see para. B-2.)
d. Column (4)-Maintenance Category. Column 4 specifies, by the listing of a work time figure in the
appropriate subcolumn(s), the category of maintenance authorized to perform the function listed in Column
3. This figure represents the active time required to perform that maintenance function at the indicated
category of maintenance. If the number of complexity of the tasks within the listed maintenance function
vary at different maintenance categories, appropriate work time figures will be shown for each category. The
work time figure represents the average time required to restore an item (assembly, subassembly,
component, module, end item, or system) to a serviceable condition under typical field operating conditions.
This time includes preparation time (including any necessary disassembly/assembly time)
troubleshooting/fault location time, and quality assurance/quality control time in addition to the time
required to perform the specific tasks identified for the maintenance functions authorized in the
maintenance allocation chart. The symbol designations for the various maintenance categories are as
follows:
NOTE
When a complete replace or repair task performed at higher
level maintenance includes lower level maintenance tasks
(equipment condition/follow-on tasks), the lower level work
time figures in the MAC must be added to the higher level
work time shown in the MAC to determine the total time to
accomplish that maintenance function.
C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator or crew
O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unit maintenance
F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct Support maintenance
H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Support maintenance
D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Depot maintenance
e. Column (5)-Tools and Equipment. Column 5 specifies, by code, those common tool sets (not
individual tools) and special tools, TMDE, and support equipment required to perform the designated
function.
f. Column (6)-Remarks. This column shall, when applicable, contain a letter code, in alphabetic
order, which shall be keyed to the remarks contained in Section IV.
B-2
TM 9-2320-280-20-3
B-4. EXPLANATION OF COLUMNS IN TOOL AND TEST EQUIPMENT REQUIREMENTS, SECTION III
a. Column (1)-Reference Code. The tool and test equipment reference code correlates with a code
used in the MAC, Section II, Column 5.
b. Column (2)-Maintenance Category. The lowest category of maintenance authorized to use the
tool or test equipment.
c. Column (3)-Nomenclature. Name or identification of the tool or test equipment.
d. Column (4)-National Stock Number. The National stock number of the tool or test equipment.
e. Column (5)-Tool Number. The manufacturer’s part number.
B-5. EXPLANATION OF COLUMNS IN REMARKS, SECTION IV
a. Column (1)-Remarks Code. The code recorded in column 6, Section II.

b. Column (2)-Remarks. This column lists information pertinent to the maintenance function being
performed as indicated in the MAC, Section II.
B-3
TM 9-2320-280-20-3
Section II. MAINTENANCE ALLOCATION CHART

(4)
(1) (2) (3) (5) (6)
Maintenance Level
Direct General
Tools and
Group Maintenance Unit Support Support Depot Equipment Remarks
Number Component/Assembly Function C O F H D Ref Code Code
01 ENGINE
0100 Engine Assembly Inspect 0.2 0.7
Test 1.0 1,37,40
Service 0.5 1,2 G
Adjust 1.0 41,42
Replace 32.7 43,145
Repair 16.0 1,7,10,43-45
Overhaul 30.0 1,7,10,44-49,

147,148,155-
161
Mount, Engine Inspect 0.1 2,144,145
Replace 1.6 1,2,43,144-
146,149
0101 Cylinder Head Replace 3.0 1,6
Repair 5.0 1,6,8
Block, Cylinder Repair 10.0 1,6-8
0102 Crankshaft Replace 4.0 1
Pulley, Crankshaft Replace 0.5 1,6
Damper, Vibration Replace 0.5 1,6
Bearings, Crankshaft Replace 4.0 1
Oil Seals, Crankshaft, Front Replace 2.0 1
Oil Seals, Crankshaft, Rear Replace 2.0 1,6,46
0103 Flywheel Replace 3.5 1,6
0104 Pistons, Connecting Rods
Rods, Connecting Replace 8.0 1,6
Bearings, Connecting Rod Replace 2.0 1,6
Pistons Replace 8.0 1,6
Rings, Piston Replace 7.0 1,6,10
0105 Valves, Camshaft, and Timing
System
Cover, Rocker Arm Replace 1.0 1,6
Valves, Intake and Exhaust Replace 3.0 6
Repair 3.0 6,8
Rocker Arm Assembly Replace 2.1 1,6
Springs, Valve Test 0.5 1,8
Replace 2.3 1,6
Rods, Push Replace 3.0 1
Lifters Replace 6.0 1,43
B-4 Change 1
TM 9-2320-280-20-3
Section II. MAINTENANCE ALLOCATION CHART (Cont'd)

(4)
(1) (2) (3) (5) (6)
Maintenance Level
Tools and
Direct General
Gears and Chain, Timing Replace 4.0 1,6,10

Camshaft Replace 4.0 1,6,10
Bearings, Camshaft Replace 4.0 1,6,45
0106 Engine Lubrication System
Pan, Oil Replace 2.0 1,2
Pump, Oil Replace 2.5 1,6
Filter, Oil Replace 0.5 1,2
Dipstick and Tube Replace 0.2 1,2,156
Oil Cooler Assembly Inspect 0.1
Replace 0.5 1,2
Repair 1.0 1
Lines, Oil Cooler Inspect 0.2
Replace 1.8 1
Valve, Crankcase Depression Inspect 0.1
Regulator Test 0.3 L
Service 0.3 1
Replace 0.3 1,2
0108 Manifold, Intake Replace 3.0 1,6
Manifold, Exhaust Replace 3.0 1,146,
150,156
03 FUEL SYSTEM
0301 Injector Nozzle, Fuel Test 0.5 1,9
Replace 0.7 1,6,49,134,
146,153
0302 Lines, Injection Pump Inspect 0.1
Replace 2.0 1,147,148
Pump, Injection Inspect 0.1
Calibrate A 1,9,59-65 A
Replace 4.0 1,147
Repair 0.6 5.0 1,9,50-57, O
158-161
Fuel Pump Test 0.3 1,2
Replace 1.0 1,2
0304 Cleaner Assembly, Air Inspect 0.2
Service 0.2 0.5 1
Replace 0.2 1
Horn, Air Induction Inspect 0.1
Replace 0.3 1,2
0306 Lines and Fittings, Fuel Inspect 0.2
Replace 3.2 1
Tank, Fuel Inspect 0.1
Replace 2.6 1,2
Change 1 B-5
TM 9-2320-280-20-3

(4)
(1) (2) (3) (5) (6)
Maintenance Level
Direct General
Tools and
Group Maintenance Unit Support Support Depot Equipment Remark
0309 Filter Assembly, Fuel Inspect 0.1

Service 0.1 0.5 1 B
Replace 0.5 2
0311 Glow Plugs Test 0.3 2
Replace 0.7 1,2,155
0312 Accelerator Linkage Inspect 0.2
Adjust 0.2 1
Replace 0.8 1,2
Hand Throttle Inspect 0.1 0.1
Adjust 0.2 1
Replace 0.5 1,2
04 EXHAUST SYSTEM
0401 Muffler Inspect 0.2
Replace 1.9 1,2
Crossover Pipe Inspect 0.2
Replace 1.2 1,2,145,
150
Tailpipe Inspect 0.2
Replace 0.5 1,2
05 COOLING SYSTEM
0501 Radiator Inspect 0.1 0.2
Test 0.5 2,66
Replace 4.3 1
Repair 3.0 1
Surge Tank Inspect 0.1
Service 0.1 0.5 1,2 C
Replace 0.6 1
0502 Shroud, Fan Inspect 0.1
Replace 4.4 1
Repair F F,M
0503 Hoses, Lines, and Clamps Inspect 0.1 0.1
Replace 2.5 1
Thermostat Test 0.2
Replace 0.3 1,2
0504 Pump, Water Replace 3.5 1,6
0505 Fan and Fan Drive Inspect 0.1 0.1
Replace 1.0 1,2,161
Repair 4.7 1,6
Pulley, Water Pump Replace 4.8 1,157
B-6 Change 1
TM 9-2320-280-20-3

(4)
(1) (2) (3) (5) (6)
Maintenance Level
Tools and
Direct General
Belts, Drive Inspect 0.1

Adjust 0.5 1,2,67
Replace 1.0 1
06 ELECTRICAL SYSTEM
0601 Alternator (60 Ampere) Inspect 0.1
Test 0.3 2
Adjust 0.3 1,163
Replace 1.0 1,2
Repair 4.0 9,68
Pulley, Alternator Replace 1.2 1,2
0603 Starter Inspect 0.2
Test 0.3 2
Replace 1.9 1,2,145,
146,149
Repair 8.3 1,9
0607 Instrument Panel
Switches Replace 0.3 1
Instruments, Gages Inspect 0.1
Replace 0.5 1
Circuit Breakers Replace 0.5 1
0608 Control, Directional Signal Inspect 0.1
Replace 0.3 1
Protective Control Box Inspect 0.1
Replace 0.3 1
0609 Headlight Inspect 0.1
Adjust 0.2 1,2
Replace 0.5 1
Lights, Composite, Front Inspect 0.1
and Rear Replace 0.1 1
0610 Sending Units and Warning Test 0.1 2
Switches Replace 0.1 1
0611 Horn Assembly Inspect 0.1
Test 0.2 2
Replace 0.3 1
Switch, Horn Test 0.2 2
Replace 0.2 1
0612 Battery Inspect 0.1
Test 0.5 2
Service 0.2 1
Replace 1.6 1
Cables, Battery Inspect 0.2
Replace 0.8 1
Repair 0.5 1,2
Change 1 B-7
TM 9-2320-280-20-3

(4)
(1) (2) (3) (5) (6)
Maintenance Level
Direct General
Tools and
0613 Wiring Harnesses

Wiring Harness, Engine Inspect 0.3
Replace 4.5 1,6
Repair 0.5 1,2
Wiring Harness, STE/ICE-R Inspect 0.3
Replace 3.7 1,6
Repair 0.5 1,2
Wiring Harness, Body Inspect 0.4
Replace 3.5 1,6
Repair 0.5 1,2
Wiring Harness, Hood Inspect 0.2
Replace 1.0 1
Repair 0.5 2
0615 Ambulance Electrical
System
Spotlight and Ceiling Inspect 0.1
Light Bulbs Replace 0.1 1
Spotlight and Ceiling Inspect 0.1
Light Assemblies Replace 0.2 1
Blackout Light Switches Inspect 0.1
Replace 0.2 1
Backup Lights Replace 0.3 1
Control Box Inspect 0.1
Replace 2.5 1
Control Box Relays, Replace 0.3 1
Switches, Fuse Blocks
Heat/Vent Control Replace 0.3 1
Panel (M996)
Heat, Vent, and Replace 10.0 1
A/C Control Box (M997)
Heat, Vent, and Replace 0.3 1
A/C Switches and Relays
200 Ampere Alternator Inspect 0.2
Test 0.3 166
Replace 1.1 1
Adjust 0.3
Repair 4.0
Lighting Wiring Harness Replace 3.5 1
NBC Control Box and Replace 4.3
Wiring Harness
B-8 Change 1
TM 9-2320-280-20-3

(4)
(1) (2) (3) (5) (6)
Maintenance Level
Direct General
Tools and
07 TRANSMISSION
0705 Shift Control and Linkage Inspect 0.1 0.2 D
Adjust 0.5 1
Replace 1.5 1,2
Repair 1.0 6
Modulator, Mechanical Adjust 0.1 2
Replace 0.6 2
Switch Neutral Start Replace 0.5 1
Detent Solenoid Replace 1.7 1,2
0708 Torque Converter Replace 3.3 1,2
0710 Transmission Assembly Inspect 0.1
Test 0.5 2,6,145
Service 0.2 1,2
Replace 5.8 1,6,144
Repair 4.0 1,6,70,80
Overhaul 13.5 1,6,10,70,
80
Transmission Mount Inspect 0.2
Replace 1.0 1,6
Gear Unit Replace 1.5 1,6,70-73
Repair 1.3 1,6,72-75
0713 Forward Clutch Replace 2.0 1,6,70-73
Repair 0.6 1,6,76,77
Direct Clutch Replace 2.0 1,6,70-73,
79
Repair 0.8 1,6,76,77
Intermediate Clutch Replace 2.0 1,6,70-73
Repair 0.8 1,6,74,75
0714 Rear Servo Replace 1.0 1,6,78
Repair 0.3 1,6,78
Front Servo Replace 1.0 1,6
Repair 1.0 1,6
Band, Front and Rear Replace 2.5 1,6,70-73,
79
Governor Inspect 0.2
Replace 0.5 1,6
Control Valve Replace 1.3 1,6
Repair 1.0 1,6,10
0721 Oil Pump, Transmission Replace 1.0 1,6,70,71,
73,80
Repair 1.6 1,6,73-75
Change 1 B-9
TM 9-2320-280-20-3

(4)
(1) (2) (3) (5) (6)
Maintenance Level
Direct General
Tools and
Seal, Oil Pump Replace 0.3 1,6,80

Oil Filter, Transmission Replace 1.5 1,2
Oil Cooler Lines Inspect 0.2
Replace 1.0 1
08 TRANSFER
0801 Transfer Case Inspect 0.1
Service 0.5 2
Replace 5.2 1,6,144
Repair 5.7 1,6,75,94- P
106,130
Overhaul 10.0 1,6,10,75
94,106,
144
Seal, Oil, Input and Output Replace 1.3 1,2,94
Shaft
Yokes, Front and Rear Replace 1.2 1,2
Bearings, Output Shaft Replace 3.0 1,2,75,
95-100
Gear, Speedometer Driven Replace 0.5 1,2,107
0803 Shift Control and Linkage Inspect 0.1 0.2 D
Adjust 0.5 1
Replace 1.0 1,2
Repair 1.0 1,2
09 PROPELLER SHAFTS
0900 Shafts, Propeller, Front Service 0.2 1,2
Replace 1.0 1,2
Repair 0.5 1.2 1,2,6 E
Shaft, Propeller, Rear Service 0.2 1,2
Replace 1.0 1,2
Repair 1.2 1,2
Joints, Universal Inspect 0.1
Service 0.3 2
Replace 1.5 1,2
10 FRONT AXLE
1000 Halfshaft Inspect 0.2
Replace 2.2 1,2
Repair 1.0 1,2
B-10 Change 1
TM 9-2320-280-20-3

(4)
(1) (2) (3) (5) (6)
Maintenance Level
Direct General
Tools and
1002 Differential Assembly Inspect 0.1

Service 0.5 1,2
Replace 5.0 1,2
Repair 10.2 1,7,75,94,
117-124
Overhaul 15.0 1,7,10,75,94,
117-124
Seal, Output Shaft, Differential Replace 1.0 1,6,117
Seal, Pinion, Differential Replace 0.3 1,6,94
Differential Cover Replace 0.5 1,2 H
1004 Knuckle and Geared Hub Inspect 0.1
Service 0.5 1,2
Replace 2.0 1,2,167
Repair 1.2 1,2,6,75, K
126-128
Bearing, Spindle, Geared Hub Adjust 0.9 1,2,127
Seal, Input, Geared Hub Replace 2.0 1,2,75,126
Seal, Spindle, Geared Hub Replace 1.0 1,2,75,127, I
128
Steering Stop Adjust 0.5 2
Replace 0.3 2
Upper Control Arm Inspect 0.1
Replace 1.0 1,2
Repair 1.0 1,2
Lower Control Arm Inspect 0.1
Replace 2.6 1,2
Repair 1.0 1,2
Ball Joint, Upper and Lower Replace 0.6 1,2,129,146,
151
11 REAR AXLE
1100 Halfshaft Inspect 0.2
Replace 1.8 1,2
Repair 1.0 1,2
1102 Differential Assembly Inspect 0.1
Service 0.5 1,2
Replace 5.0 1,2
Repair 10.0 1,7,75,94,
117-124
Overhaul 15.0 1,7,10,75,94,
117-124
Seal, Output Shaft, Differential Replace 1.0 1,6,117
Seal, Pinion, Differential Replace 0.3 1,6,94
Change 1 B-11
TM 9-2320-280-20-3

(4)
(1) (2) (3) (5) (6)
Maintenance Level
Direct General
Tools and
Group Maintenance Unit Support Support Depot Equipment Remark
Number Component/Assembly Function C O F H D Ref Code s
1104 Knuckle and Geared Hub Inspect 0.1

Service 0.5
Replace 2.0 2,167
Repair 1.2 1,2,75,126,
128 K
Bearing, Spindle, Geared Hub Adjust 0.9 1,2,127
Seal, Input, Geared Hub Replace 2.0 1,2,75,126
Seal, Spindle, Geared Hub Replace 1.0 1,2,75,127,
128
Upper Control Arm Inspect 0.1
Replace 1.0 1,2
Repair 1.0 1,2
Lower Control Arm Inspect 0.1
Replace 2.6 1,2
Repair 1.0 1,2
Ball Joint, Upper and Lower Replace 0.6 1,2,129,146,
151
12 BRAKES
1201 Parking Brake Lever Adjust 0.3
Replace 1.0 1,2
Parking Brake Cable Adjust 0.5 1,2
Replace 1.0 1,2
Parking Disc Brake Pad Inspect 0.2
Replace 1.0 1,2
Dual Service/Parking Adjust 0.5 1,2
Brake Cable, Right Rear Replace 0.7 1,2
Dual Service/Parking Adjust 0.5 1,2
Brake Cable, Left Rear Replace 0.5 1,2
Dual Service/Parking Inspect 0.1
Calipers, Rear Replace 1.0 1,2,162
Dual Service/Parking Inspect 0.2
Pads, Rear Replace 1.0 1,2
1202 Service Brakes Test 0.1
Calipers, Front and Rear Replace 1.0 1,2,152,162
Repair 0.5 1,6
Pads, Front and Rear Inspect 0.2
Replace 1.0 1,2,152
Rotor, Front and Rear Inspect 0.1 1
Replace 1.2 1,2
Repair 1.5 1,6
B-12 Change 1
TM 9-2320-280-20-3

(4)
(1) (2) (3) (5) (6)
Maintenance Level
Direct General
Tools and
1204 Master Cylinder Inspect 0.1

Service 0.2 2
Replace 0.5 1,2
Brake Lines Inspect 0.2
Replace 1.5 1
Proportioning Valve Replace 0.6 1,2
1205 Hydro-Boost Replace 1.3 1,2
1206 Pedal, Brake Replace 1.0 1,2,146,153
13 WHEELS AND TIRES

1301 Front Wheel Toe-In Align 0.5 1
Rear Wheel Toe-Out Align 0.5 1
1311 Wheel and Tire Assembly Inspect 0.1 0.1
Service 0.2
Replace 0.4 0.1 1,2 N
Repair 0.5 1,2,130
Runflat Assembly Replace 2.2 1,2,4,144,
154,131 J
14 STEERING
1401 Mechanical Steering
Wheel, Steering Replace 0.7 1,2
Column, Steering Inspect 0.1
Replace 1.8 1,2
Intermediate Shaft, Steering Service 0.2 1,2
Replace 0.5 1,2
Tie Rod Assembly Inspect 0.1
Service 0.2 1,2
Adjust 0.5 1,2,167
Replace 0.5 1,2,129
Center Link Inspect 0.1 1,2
Replace 0.3 1,2,167
Pitman Arm Inspect 0.1
Replace 1.0 1,2,129
Idler Arm Inspect 0.1
Replace 0.3 1,2,129
Camber/castor Adjustment 2.2 1,138.1
1407 Gear, Power Steering Inspect 0.2
Replace 0.5 1,2
Repair 3.7 1,6,132,135
Change 1 B-13
TM 9-2320-280-20-3

(4)
(1) (2) (3) (5) (6)
Maintenance Level
Direct General
Tools and
1410 Pump, Power Steering Inspect 0.1 0.1

Test 0.5 1,2,
136-138
Service 0.2 1,2
Replace 1.0 1,2
Repair 1.0 1,6
Pulley, Power Steering Pump Replace 0.5 1,2,137
1411 Hoses, Lines, and Fittings Inspect 0.2
Power Steering Replace 1.0 1
15 FRAME
1501 Frame Assembly Inspect 0.5
Repair F 1,5 F
Crossmember, Transmission Replace 2.0 1
Crossmember, Front, Inspect 0.2
Brackets, and Supports Replace 4.5 1,6
Repair 2.0 1,5
Crossmember, Rear Replace 2.0 1,2
Bumpers Replace 0.5 1,2
1503 Pintle, Towing Inspect 0.1
Service 0.1 1
Replace 1.0 1,2
Repair 0.2 1,2
16 SPRINGS AND SHOCK

ABSORBERS
1601 Springs Inspect 0.1
Replace 1.0 1,2
1604 Absorbers, Shock Inspect 0.1 0.1
Replace 0.8 1,2
1605 Rod, Stabilizer Replace 1.5 1,2
Rod, Radius Inspect 0.1
Replace 1.0 1,2
Repair 0.5 1,2
18 BODY AND HOOD

1801 Body Inspect 0.1
Service 1.0 1
Replace F 1,6 F
Repair F 1,2,139,140 F
Hood Inspect 0.1
Replace 1.3 1,2
Repair F 1,6 F
B-14 Change 1
TM 9-2320-280-20-3

(4)
(1) (2) (3) (5) (6)
Maintenance Category
Direct General
Tools and
Doors, Rear Inspect 0.1

Replace 0.2 1
Repair F 1,5,139 F
Cover, Engine Access Inspect 0.1
Replace 0.1 1
Repair F 1,5,139 F
1802 Windshield Assembly, Folding Inspect 0.1
Replace 2.0 1,2
Repair F 1,5,139 F
Windshield Assembly, Fixed Inspect 0.1
Replace 2.0 1,6
Repair F 1,5,139 F
Windshield Glass Inspect 0.1
Replace 1.0
1806 Seats Inspect 0.1
Replace 1.0 1,2
Repair 1.0 1,2
Seatbelts Inspect 0.1
Replace 0.8 1,2
1808 Stowage Racks, Boxes, Inspect 0.1
and Straps Replace F 1,2 F
Repair F 1,2 F
Tailgate Inspect 0.1
Replace 0.4 1,2
Repair 1.0 1,5,139
1812 TOW Carrier and Armament
Carrier (M966, M966A1, M1025,
M1025A1, M1025A2, M1026,
M1026A1, M1036, M1043,
M1043A1, M1043A2, M1044,
M1044A1, M1045, M1045A1,
M1045A2, M1046, M1046A1,
M1121)
Doors, Crew Inspect 0.1
Adjust 0.3 1,2
Replace 0.2 1
Repair F 1,5,139 F
Door, Cargo Shell Inspect 0.1
Adjust 0.3 1,2
Replace 2.5 1,2
Repair F 1,2,139 F
Glass, Door Inspect 0.1
Replace 1.0 1
Weapon Station Inspect 0.1
Replace 1.5 1,6
Gunners Platform Inspect 0.1
Replace 0.5 1
Change 1 B-15
TM 9-2320-280-20-3
Section II. MAINTENANCE ALLOCATION CHART (Cont’d)

(4)
(1) (2) (3) (5) (6)
Maintenance Level
Direct General
Tools and
S250 Shelter Carrier

(M1037, M1042)
Support, Shelter Inspect 0.1
Replace 2.0 1,2
Sling, Tiedown Inspect 0.1
Replace 0.3 1
Soft Top Ambulance
(M1035, M1035A1)
Rack, Litter Inspect 0.1
Replace 1.5 1,2,145
Ambulance – 2-Litter
(M996, M996A1),
4-Litter (M997, M997A1
M997A2)
Door, Rear Inspect 0.1
Adjust 0.4 1,2
Replace 0.3 1,2
Door Latch and Handles, Inspect 0.1
Rear Replace 0.5
Steps, Rear Inspect 0.1
Replace 0.5 1,2
Repair 0.6 1,2
Litter Rack, Upper
Doors, Stowage Inspect 0.1
Replace 1.0 1,2,139
Doors, Bulkhead Inspect 0.1
Replace 2.0 1,2,139
Extension Rails, Litter Repair 1.2 1,2
NBC Heaters and Brackets Inspect 0.1
Replace 0.8 1,2
NBC Filters and Brackets Inspect 0.1
Replace 0.7 1,2
Ambulatory Patient Seat Inspect 0.1
Replace 0.6 1,2
Heat/Vent Panel (M996,
M996A1) Replace 0.3 1,2
Heater (M996, M996A1) Adjust 1.5 1,6
Replace 0.8 1,2
Repair 3.5 1,6
Heater (M997, M997A1, Adjust 1.5 1,6
M997A2) Replace 0.8 1,2
Repair 3.5 1,6
B-16 Change 1
TM 9-2320-280-20-3

(4)
(1) (2) (3) (5) (6)
Maintenance Level
Direct General
Tools and
20 WINCH
2001 Winch Assembly Service 0.2
Replace 0.6 1,2
Repair 4.0 1,9,159
Cable, Winch Inspect 0.5
Service 0.5 1
Replace 0.4 1,2
Control Assembly, Winch Inspect 0.1
Replace 0.1 1,2
22 BODY ACCESSORY ITEMS
2201 Bows Inspect 0.1
Service 0.5
Replace 1.0 1
Repair 0.5 1
Cover, 2-Door Cab Inspect 0.1 1
Service 0.5
Replace 0.5 1
Repair F 1,7 F
Cover, 4-Door Cab Inspect 0.1 1
Service 0.5
Replace 1.5 1
Repair F 1,7 F
Cover, 2-Door Cargo Inspect 0.1
Service 0.5
Replace 1.0 1
Repair F 1,7 F
Cover, 4-Door Cargo Inspect 0.1
Service 0.5
Replace 1.0 1
Repair F 1,7 F
Door, Front Inspect 0.1
Service 0.1
Adjust 0.4 1,2
Replace 0.2 1 F
Repair F 1,7 F
Cover, Rear Door Inspect 0.1
Service 0.1
Replace 0.2 1
Repair F 1,7 F
Curtain, Body Cover Inspect 0.1
Service 0.5
Replace 1.0 1
Repair F 1,7 F
Change 1 B-17
TM 9-2320-280-20-3

(4)
(1) (2) (3) (5) (6)
Maintenance Level
Direct General
Tools and
2202 Motor, Windshield Wiper Test 0.3 2

Replace 0.5 1,2
Arm Assembly, Wiper Inspect 0.1
Replace 0.2 1,2
Linkage, Wiper Replace 0.5 1
Motor and Reservoir Test 0.2 2
Assembly, Washer Service 0.2 1
Replace 0.1 1,2
Nozzle, Washer Replace 0.5 1
Mirror, Rearview Inspect 0.1
Adjust 0.1
Replace 0.2 1,2
Reflectors Replace 0.2 1
Steering Wheel Lock Replace 1.0 1,139
2207 Ducting, Defroster and Heater Replace 1.0 1
Controls, Defroster and Heater Replace 1.0 1
Heater Assembly Replace 1.4 1,2
2210 Data Plates Replace 0.5 1,139
33 SPECIAL PURPOSE KITS

3303 Arctic Winterization Kit Install 8.0 6,139-142
Arctic Heater Kit Install 8.0 6,139-142
Pump and Lines, Fuel Inspect 0.1 0.2
Replace 1.0 1,2
Heater Inspect 0.1
Replace 0.2 1
Control, Heater Replace 0.5 1
Repair 1.0 1
2-Man Crew Top Kit Install 2.0 139
Cover, 2-Door Cab Inspect 0.1
Replace 0.5 1
Repair F 7 F
Curtain, Body Cover Inspect 0.1
Replace 0.5 1
Repair F 7 F
3305 Deep Water Fording Kit Install 4.0 1,2
Snorkel, Intake and Exhaust Inspect 0.2 0.2
Install 2.0
Replace 1.5 2
Venting Inspect 0.1 0.1
Replace 1.0 1
B-18 Change 1
TM 9-2320-280-20-3

(4)
(1) (2) (3) (5) (6)
Maintenance Category
Direct General
Tools and
3307 100 AMP Alternator Kit Inspect 0.2

Test 0.3 4
Install 2.5 2
Replace 1.0 2
Repair 1.0 9
Troop Seat Kit Inspect 0.1
Install 2.0 1,2
Replace 0.8 2
Repair 1.0 4
Communications Kit Install 3.0 1,2
Replace F 1 F
47 GAGES (NON-ELECTRICAL)
4701 Speedometer Replace 0.2 1
Cable and Housing Replace 0.5 1
4702 Gage, Air Restriction Inspect 0.1
Replace 0.1 1
52 AIR CONDITIONER
Ambulance (M997, M997A1,
M997A2)
5203 Compressor, A/C Replace 1.5 1,2
Repair 3.0 1,2,143
Bracket Mounting, Replace 0.4 1
Compressor
5205 Service Valve, A/C Replace 0.6 2
5217 A/C Lines and Fittings Inspect 0.1
Replace 1.5 1,6
Air Conditioner Inspect 0.1
Test 0.3
Service 1.6 2,19,143
5230 Coil, Condensor Replace 1.6 2
5241 Coil, Evaporator Replace 2.0 2
Repair 0.4 2
5243 Blower Motor, Condenser Replace 0.8 1
Blower Motor, Evaporator Replace 1.0 1
Repair 0.6
5246 Bottle, Dryer Replace 0.3 1
Change 1 B-19
TM 9-2320-280-20-3
Section III. TOOL AND TEST EQUIPMENT REQUIREMENTS

(1) (2) (3) (4) (5)
Reference Maintenance National/NATO Tool
Code Category Nomenclature Stock Number Number
1 O Tool Kit, General Mechanic's Automotive 5180-00-177-7033

2 O Shop Equipment, Automotive Maintenance 4910-00-754-0654
and Repair: Organizational Maintenance,
Common #1, Less Power
Supplemental #1, Less Power
Common #2, Less Power
5 O Tool Kit, Body and Fender 5180-00-754-0643
6 F Shop Equipment, Automotive Maintenance 4910-00-754-0705
and Repair: Field Maintenance, Basic,
Less Power
and Repair: Field Maintenance,
and Repair: Field Maintenance,
9 F Shop Equipment, Fuel and Electrical 4940-00-754-0714
System Engine: Field Maintenance,
Basic, Less Power
and Repair: Field Maintenance, Wheeled
Vehicles, Post, Camp and Station, Set A
11 O Special Tool Kit, Organizational 5180-01-387-5455 57K0267
Special Tool Kit, Organizational,
Supplemental (“A2” series only) 5180-01-410-8467
12 F Special Tool Kit, Direct Support 5180-01-389-7560 57K0268
13 H Special Tool Kit, General Support 5180-01-389-7561 57K0266
Special Tool Kit, General Support,
Supplemental (“A2” series only) 5180-01-408-7050
NOTE
The optional metric tool sets listed below
are required for maintenance of this
vehicle.
14 O Metric Wrench Set, 10-32 mm, 5120-01-119-0010
Open End/Box End
15 O Metric Socket Set, 6-26 mm, Std., 6 pt., 5120-01-117-3876
3/8 in. Drive
B-20 Change 1
TM 9-2320-280-20-3
Section III. TOOL AND TEST EQUIPMENT REQUIREMENTS (Cont'd)

(1) (2) (3) (4) (5)
16 F Metric Socket Set, Std., 6 pt., 5120-01-112-9543
3/8 in. Drive, Deep Reach
17 F Metric Allen Wrench Kit 5120-01-046-5079
18 F Metric Tap and Die Kit 5136-01-119-0005
19 F Tool Kit, Service Refrigeration Unit 5180-00-596-1474
19.1 F Parts Kit, FR-12 Refrigerant 57K3534
01 ENGINE
20 F Adapter, Compression Gage 4910-01-238-2551 J 26999-30
21 F Quick Disconnect 4730-01-842-5266 J 25209
22 F 90° Elbow 4730-00-854-5837 MS51815
23 F Remover, Hydraulic Valve Lifter 5120-01-209-6870 J 29834
24 DELETED
25 F Engine Lifting Sling 4910-01-193-7808 J 33139
26 F Tester, Engine Compression 4910-01-355-7815 J 6692A
27 DELETED
28 DELETED
29 DELETED
30 DELETED
31 DELETED
32 DELETED
33 DELETED
34 DELETED
35 DELETED
36 DELETED
37 DELETED
38 DELETED
39 DELETED
40 DELETED
41 F Gauge, Timing 6620-01-231-3671 MT95
42 F Meter, Dynamic Timing 5180-01-186-3114 J 33127
43 DELETED
44 H Stand – Engine Repair 4910-00-506-0037 1725A
45 DELETED
Change 1 B-21
TM 9-2320-280-20-3

(1) (2) (3) (4) (5)
46 H Installer, Crankshaft Rear Oil Seal (6.2L) 5120-01-210-8792 J 33153

H Installer, Crankshaft Rear Oil Seal (6.5L) J 39084
47 H Remover and Installer, Camshaft 5120-01-206-3818 J 35178
Bearings
48 F Pliers, Needle Nose, 90° 5120-01-174-4496 497ACP
03 FUEL SYSTEM
49 F Remover, Fuel Injection Nozzle 5120-01-171-5233 J 29873
50 H Installer, Drive Shaft Bearing 5120-01-208-7771 23805
51 H Installer, Drive Shaft Seal 5120-01-208-7752 22727
52 H Kit, Throttle and Shutoff Shaft Bushing 5180-01-189-0448 18411
53 H Socket, Torx Drive, T27 5120-01-367-3534 FTX27A
54 H Support, Governor Weight 5120-01-197-0236 16313
55 H Wrench, End Cap 5120-01-207-5563 20548
56 H Roller to Roller Setting Tool 5120-01-200-4526 19969
57 H Fixture, Holding 5120-01-208-7753 23615
58 H Mandrel, Pilot Tube 5120-01-208-1767 16314
59 H Extractor, Delivery Valve Test Set 5120-00-816-7859 26081
60 H Test Set, Calibration
61 H Linkage Gap Tool 5210-01-249-0370 23080
62 H Indicator, Automatic Advance 5210-01-249-0368 23745
63 O Block, Throttle Lever Gauge 4820-01-179-4869 J 33043
64 H Protractor 6675-01-247-2286 22089
65 H Gage, Air Timing 5220-01-247-0361 23715
05 COOLING SYSTEM
66 O Tester, Radiator 4910-01-018-4373 ST255A
67 O Gage, Belt Tension 6635-01-093-3710 J 23600B
06 ELECTRICAL SYSTEM
68 F Socket, Torx 5120-01-227-3159 TLE60
69 O Starter Pinion Core Shaft Nut Driver 9530-00-236-7723
9530-00-061-0463
07 TRANSMISSION (3L80)
70 H Fixture, Transmission Holding 5120-01-198-7583 J 8763-02
71 H Base, Transmission Holding Fixture 5120-01-144-4484 J 3289-20
72 H Holding Tool, Transmission Gear 4910-01-178-8865 J 21795-02
Unit Assembly
B-22 Change 1
TM 9-2320-280-20-3

(1) (2) (3) (4) (5)
73 H Adapter, Slide Hammer, 3/8-16 5120-01-130-8865 J 6471-2
74 H Bushing Service Set 5180-01-195-9777 J 21465-01
75 O Driver Handle 5120-01-026-1666 C4171
76 H Compressor, Clutch Spring 5120-01-210-8793 J 4670-01
77 H Adapter, Clutch Spring Compressor 4910-01-210-8793 J 21664
78 H Gage, Band Apply Selector 4910-01-178-0722 J 21370
79 H Alignment Tool, Intermediate 4910-01-209-0729 J 24396
Clutch Pack
80 F Installer, Oil Pump Seal 5120-01-176-1845 J 21359A
07 TRANSMISSION (4L80-E)
81 H Adapter, Holding Tool, J 38655
Use W/J 8763-02
82 H Adapter, Torque, 3/8 5120-01-367-3536 FTX40A
83 H Removal/Installer Tool, Oil Pump J 37789-A
84 H Installer/Remover, Gear Unit J 38868-A
85 H Adapter, Clutch Compressor J 38734
Spring , Use W/J 23327
86 H Seal Protectors, Forward Clutch J 38732
Piston, Kit Includes J 38732-1
and J 21362-1
87 H Compressor, Clutch Spring 4910-01-178-0724 J 23327
88 H Adapter, Compressor, Clutch 5120-01-410-8216 J 25018-A
Spring, Use W/J 23327
89 H Seal Piston and Housing, Fourth J 38731
Clutch
90 H Installer/Sizer/Pusher, Turbine J 38736
Shaft Seal, Includes J 38731-1,
J 38731-2, J 38731-3
91 H Installer/Sizer/Pusher, Oil Pump J 38739
Seal Ring J 38739-1, J 38739-2,
J 38739-3
92 H Gauge Pin, Band Apply, J 21370-10
Use W/J 38737
93 H Tool Pin Checking, Band Apply J 38737
93.1 O Jumper, Throttle Position 6150-01-412-7774 12460120
Sensor Adjustment
93.2 O Case, Transmission Diagnostic 5120-01-408-8173 12460136
Cable
93.3 O Diagnostic Switch Cable 6150-01-410-8215 12460137
Change 1 B-23
TM 9-2320-280-20-3

(1) (2) (3) (4) (5)
08 TRANSFER (218)
94 O Installer, Yoke Seal 4910-01-179-5530 J 29162
95 H Adapter, Slide Hammer 5120-01-391-5131 J 6471-8
96 H Installer, Front Output Shaft 5120-01-195-2721 J 29163
Rear Bearing
97 H Installer, Rear Output Shaft Bearing 5120-01-196-0084 J 29166
98 H Installer, Front Output Shaft 5120-01-170-3278 J 29167
Front Bearing
99 H Remover, Front Output Shaft 5120-01169-4876 J 29168
Front Bearing
100 H Remover, Universal Bearing and 5120-01-201-7857 J 29369
Bushing
101 H Remover, Input Gear Bearing 5120-01-195-4551 J 29170
102 H Installer, Input Gear Bearing 5120-01-185-7955 J 29169
103 H Installer, Rear Retainer Bearing 5120-01-185-8024 J 7818
104 H Installer, Main Shaft Bearing 5120-01-265-4872 J 36307
105 H Remover, Annulus Gear Bushing 5120-01-185-7956 J 29185
106 H Installer, Annulus Gear Bushing 5120-01-247-6629 J 29185-2
107 O Mirror, Inspection 5120-00-618-6902 J 35219
08 TRANSFER (242)
108 H Installer, Bushing Remover/Bearing 5120-01-357-3633 J 33826
109 H Installer, Mainshaft Pilot Bearing J 39636
110 H Installer, Input Gear Seal 5120-01-357-3632 J 33831
111 H Installer, Output Shaft Front Bearing 5120-01-357-3630 J 33833
112 F Installer , Output Shaft Seal 5120-01-227-1680 J 22661
113 H Remover, Extension Housing Bushing 5120-01-357-3631 J 33839
114 H Bearing Tool 5120-01-357-9123 J 9276-3
115 H Installer, Extension Housing Seal 5120-01-361-3101 J 33843
116 H Installer, Bearing and Bushing 5120-01-185-7968 J 29174
116.1 O Installer, Inserter J 38869
116.2 O Installer, Seal 6888
116.3 O Handle, Drive 5120-01-026-1666 C-4171
116.4 H Remover, Output Shaft Front Bearing J 33832
10 AND 11 FRONT AND REAR AXLE

117 F Installer, Axle Shaft and Seal 5120-01-187-3659 J 33142
118 H Adapters, Axle Holding Fixture 5120-01-218-8235 J 33149-A
B-24 Change 1
TM 9-2320-280-20-3
(1) (2) (3) (4) (5)

119 H Spreader, Differential Housing 4910-00-105-2823 W129

120 H Remover, Pinion Rear Bearing Cup 5120-01-185-7957 J 21786
121 H Remover, Pinion Front Bearing Cup 5120-01-187-3660 J21787
122 H Installer, Pinion Rear Bearing Cup 5120-01-185-7962 J 8608
123 H Installer, Pinion Front Bearing Cup 5120-01-185-7964 J 8611-01
124 H Set, Pinion Setting Gage 5180-01-216-8643 J 35199
125 H Set, Pinion Setting Gauge 5180-01-363-8079 J 39524
126 O Installer, Geared Hub Input Seal 5120-01-187-3607 J 33143
127 O Wrench, Geared Hub Locknut 5120-01-185-7963 J 33144
128 O Installer, Geared Hub Spindle Seal 5120-01-229-0842 J 35184
129 O Pickle Fork 5120-00-880-4268 11595179
13 WHEELS AND TIRES

130 O Bubble Balancer 4910-01-093-0167 MIL-B-45989
131 O Runflat Compressor 5120-01-335-5847 J 39250 or
528236
14 STEERING SYSTEM
132 F Remover and Installer, Adjuster Plug 5120-01-185-7965 J 6221
Bearing
133 F Remover and Installer, Pitman Shaft 5120-01-082-6447 J 6278
Bearing
134 F Wrench, Spanner 5120-01-082-6436 J 7624
135 F Arbor, Rack Piston 5120-01-179-1032 J 21552
136 O Analyzer, Power Steering 4910-01-185-7966 12342943
137 O Installer, Power Steering Pump Pulley 4910-01-179-2517 J 25033-B
138 O Adapter 5120-01-231-1709 J 33141
138.1 H Equipment, Alignment 4910-01-154-1820 DFP 134
18 BODY AND HOOD

139 O Tool Kit, Riveter 5180-01-201-4978 D-100-MIL-1
140 O Puller, Head, Right Angle 5130-01-044-1796 H763-456
141 F Puller, Head, Offset 5130-01-329-0509 H781-456
142 F Puller, Head, Straight 5130-01-104-5370 H749A-456
52 AIR CONDITIONER
143 F Tool Kit, Compressor 5180-01-267-2907 J 29642-C
Change 1 B-25
TM 9-2320-280-20-3

(1) (2) (3) (4) (5)
Code Category Number
Nomenclature Stock Number
MULTIPURPOSE TOOLS
144 O Adapter, Torque, 9/16 in. 5120-01-173-6253 SRES 18
145 O Adapter, Torque, 3/4 in. 5120-01-173-6250 SRES 24
146 O Adapter, Socket, 3/8 in. to 1/2 in. Drive 5120-00-240-8702 11655788-2
147 F Crowfoot, 3/8 in. Drive, 16 mm 5120-01-242-8165 J 35159
148 F Crowfoot, 3/8 in. Drive, 19 mm 5120-01-230-9421 J 35160
149 O Crowfoot, 3/8 in. Drive, 5/8 in. 5120-00-184-8398 FC20
150 O Crowfoot, 3/8 in. Drive, 9/16 in. 5120-00-184-8397 FC 18A
151 O Crowfoot, 3/8 in. Drive, 15/16 in. 5120-00-184-8403 FC-30A
152 O Crowfoot, 3/8 in. Drive, 14 mm 5120-01-079-8023 FCOM14
155 O Socket, Deep Well, 12 pt., 3/8 in. 5120-00-277-1463 FVS121
156 O Driver, Hex-Head, 8 mm 5120-01-053-4159 FAM8A
157 O Driver, Hex-Head, 6 mm 5120-01-055-1308 FAM6A
158 O Driver, Hex-Head, 1/8 in. 5120-01-016-9202 J 35171
159 F Driver, Hex-Head, 5/32 in. 5120-01-367-3456 FA5A
160 O Driver, Hex-Head, 1/4 in. 5120-00-596-8508 FA8A
161 O Driver, Hex-Head, 5/16 in. 5120-00-683-8602 FA10B
162 O Driver, Hex-Head, 7 mm 5120-01-105-4110 FAM 7
163 O Driver, Hex-Head, 3/16 in. 5120-00-683-8597 FA6A
164 O “C” Clamp 5120-01-180-0908 A-A-429
165 O Connector Repair Kit 5180-00-876-9336 7550526
166 O Multimeter 6625-01-139-2512 AN/PSM-45
167 O Puller, Mechanical 5120-01-011-7938 C-3894-A
168 O Socket, 1-1/2 in. Drive 3/4 in. 5120-00293-0094 47148
169 O Puller, Steering Wheel 5120-00-620-0020 6200020
170 O Vice Insert 5120-00-221-1506 404-4
171 O Universal Joint Bearing Kit 5120-01-210-4096 7057
B-26 Change 1
TM 9-2320-280-20-3
Section IV. REMARKS
(1)
REMARKS (2)
CODE REMARKS
A Calibration time will be established when support equipment requirements are iden-
tified.
B Operator drains water from fuel filter assembly. All other service is performed at
unit level.
C Operator replenishes coolant. All other service is performed at unit level.
D Operator inspects shift lever. All other inspections are performed at unit level.
E Direct support maintenance repairs coupling shaft by replacing center bearing. All
other repair is performed at unit level.
F In this category, no specific times can be established. Time required for repair will
depend on the extent of repair required for damaged components.
G Simplified test equipment/internal combustion engine (STE/ICE-R) testing times
may vary depending on the type of tests being performed.
H For vehicles with new brake adapters, P/N 10453002.
I It is authorized to remove spindle to replace the seal. All other repair is performed
at direct support level.
J Runflat compressor to be used with rubber runflat.
K If the puller kit is not available at unit level, it can be found in the GSA catalogue,
Blind Hole Puller Set, NSN 5120-00-140-3557.
L This tool can be found in the MCRL or GSA catalogue,
Manometer, U-Tube, NSN 6685-00-857-4895.
M Fan shroud repair is limited to repairs that can be made using fiberglass repair kit
(Appendix C, Item 50). Only these repairs that can be made while the shroud is
installed on the vehicle are authorized.
N Operator can remove and replace wheel assembly, but must notify unit maintenance
to tighten lug nuts to proper torque as soon as possible.
O Direct support replaces fuel injection pump governor cover gasket, shut-off solenoid,
and cold advance solenoid.
P Direct support can reseal transfer case and rear transfer case housing with silicone
sealant (RTV), NSN 6850-01-159-4844.
Change 1 B-27/(B-28 blank)

TM 9-2320-280-20-3
APPENDIX C
EXPENDABLE/DURABLE SUPPLIES
AND MATERIALS LIST
SECTION I. INTRODUCTION
C-1. SCOPE
This appendix lists expendable/durable supplies and materials you will need to maintain the M998
series vehicles. These items are authorized to you by CTA 50-970, Expendable Items (Except Medical,
Class V, Repair Parts, and Heraldic Items).
C-2. EXPLANATION OF COLUMNS
a. Column (1)-Item Number. This number is assigned to each entry in the listing and is referenced in
“Initial Setup” of applicable tasks under the heading of “Materials/Parts.”
b. Column (2)-Level. This column identifies the lowest level of maintenance that requires the listed item.
C — Operator/Crew
O — Unit Maintenance
c. Column (3) - National Stock Number. This is the National stock number assigned to the item; use it
to request or requisition the item.
d. Column (4) - Description. Indicates the Federal item name and, if required, a description to identify
the item. The last line for each item listing indicates the Commercial and Government Entity Code (CAGEC)
in parentheses followed by the part number.
e. Column (5) - Unit of Measure (U/M). Indicates the measure used in performing the actual maintenance
function. This measure is expressed by an alphabetical abbreviation (QT, GAL.). If the unit of measure differs
from the unit of issue, requisition the lowest unit of issue that will satisfy your requirements.
C-1
TM 9-2320-280-20-3
Section II. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST
(1) (2) (3) (4) (5)
NATIONAL
ITEM STOCK
NUMBER LEVEL NUMBER DESCRIPTION U/M
1 O ADHESIVE: plastic cement

(04963) 1099
8040-01-126-1422 1 Quart Can QT
2 O ADHESIVE: ethyl-2-cyanoacrylate, low viscosity
(81349) MIL-A-46050C
8040-00-826-3535 1 Ounce Bottle OZ
2.1 O ADHESIVE: sealant, gray, Uniroyal
(89619) SILAPRENE M6325-11
8030-01-347-0964 11 Ounce Cartridge OZ
3 O ADHESIVE: silicone, black
(01139) RTV-103
4 O ADHESIVE: synthetic, rubber
(GA100AJ1)
8040-00-165-8614 1 Quart Can QT
5 O ADHESIVE: silicone, RTV
(81349) MIL-A-46164
6 O ADHESIVE: plumbing, solvent cement
(81349) MIL-A-22010
8040-00-573-1502 1 Pint Container PT
7 O ADHESIVE: type II, class II
(80244) MIL-A-46050-C
8040-01-167-2613 5 Ounce Tube OZ
8040-01-090-9320 1 Pint PT
8 O ADHESIVE: general trim, spray
(04963) 051135 08080
8040-01-215-3426 24 Ounce Can OZ
9 O ADHESIVE SEALANT: RTV silicone rubber, clear
(71984) SILASTIC 737 RTV
N/A 3 Ounce Tube OZ
N/A 10.3 Ounce Cartridge OZ
N/A 5.5 Gallon Pail GAL.
9.1 O ADHESIVE:
(71984) 732 RTV
C-2 Change 1
TM 9-2320-280-20-3
Section II. EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST (Cont’d)
(1) (2) (3) (4) (5)
NATIONAL
ITEM STOCK
10 O ADHESIVE-SEALANT: silicone, RTV, general purpose

(80244) MIL-A-46106, type I
8040-00-833-9563 5 Ounce Tube OZ
11 C ANTIFREEZE: arctic-type
(81349) MIL-A-11755
6850-00-174-1806 55 Gallon Drum GAL.
12 C ANTIFREEZE: ethylene glycol, inhibited
heavy-duty, single package
(81349) MIL-A-46153
6850-00-181-7929 1 Gallon Container GAL.
13 O ANTISEIZE COMPOUND: conductive
(81349) MIL-A-907
8030-00-059-2761 1 Pound Can LB
14 C BRAKE FLUID: silicone, automotive,
all weather, operational and preservative
(81349) MIL-B-46176
9150-01-102-9455 1 Gallon Can GAL.
9150-01-123-3152 5 Gallon Can GAL.
15 CHALK, MARKING:
(81348) SS-C-255
7510-00-223-6701 1 Gross GR.
16 O CLEANING AND LUBRICATING COMPOUND:
electrical (81349) MIL-C-83360
6850-00-003-5295 16 Ounce Can OZ
17 C DETERGENT: general purpose, liquid
(81349) MIL-D-16791
17.1 C DETERGENT: laundry
(81348) PD-245
7930-00-985-6904 20 oz. box OZ
18 C DRYCLEANING SOLVENT:
(81348) P-D-680, type II
6850-00-110-4498 1 Pint Can PT
6850-00-274-5421 5 Gallon Drum GAL.
6850-00-285-8011 55 Gallon Drum GAL.
6850-00-637-6135 Bulk GAL.
Change 1 C-3
TM 9-2320-280-20-3
(1) (2) (3) (4) (5)
N AT I O N A L
ITEM STOCK
19 C FUEL OIL: diesel, regular, DF-2

(81348) VV-F-800
9140-00-286-5295 5 Gallon Can GAL.
9140-00-286-5296 55 Gallon Drum GAL.
20 C FUEL OIL: diesel, winter, DF-1
(81348) VV-F-800
9140-00-286-5287 5 Gallon Drum GAL.
9140-00-286-5288 55 Gallon Drum GAL.
21 C FUEL OIL: diesel, arctic, DF-A
(81348) VV-F-800
9140-00-286-5282 5 Gallon Can GAL.
9140-00-286-5284 55 Gallon Drum GAL.
22 C GREASE: automotive and artillery
(81349) MIL-G-10924
9150-00-190-0904 1-3/4 Pound Can LB
9150-00-190-0905 6-1/2 Pound Can LB
23 O GREASE: ball and roller bearing
(73219) 18901
9150-01-095-5512 Case, 24/14 Ounce Cans OZ
24 O GREASE: dielectric colloid
(72872) 112X
N/A 1 Gallon Container GAL.
25 O GREASE: lithium base w/molybdenum
disulfide (60218) LS2267
9150-01-015-1542 14.5 Ounce Cartridge OZ
26 C HYDRAULIC FLUID: transmission
(24617) Dexron® II
9150-00-698-2382 1 Quart Can QT
9150-00-657-4959 5 Gallon Can GAL.
27 C HYDRAULIC FLUID: transmission
(24617) Dexron® III
9150-01-353-4799 1 Quart Can QT
1950-01-114-9968 55 Gallon Drum GAL.
27.1 O LUBRICANT: run flat (62161) 12460308-1
55 Gallon Drum GAL.
C-4 Change 1
TM 9-2320-280-20-3
(1) (2) (3) (4) (5)
NATIONAL
ITEM STOCK
28 C LUBRICATING OIL: gear, multipurpose, GO 75

(81349) MIL-L-2105
9150-01-035-5390 1 Quart Can QT
9150-01-035-5391 5 Gallon Drum GAL.
29 C LUBRICATING OIL: gear, multipurpose, GO 80/90
(81349) MIL-L-2105
9150-01-035-5392 1 Quart Can QT
9150-01-035-5393 5 Gallon Drum GAL.
30 C LUBRICATING OIL: internal combustion

engine, arctic, OEA
(81349) MIL-L-46167
9150-00-402-4478 1 Quart Can QT
9150-00-402-2372 5 Gallon Drum GAL.
9150-00-491-7197 55 Gallon Drum GAL.
engine, tactical service, OE/HDO 10
(81349) MIL-L-2104
9150-00-189-6727 1 Quart Can QT
9150-00-186-6668 5 Gallon Can GAL.
9150-00-191-2772 55 Gallon Drum GAL.
engine, tactical service, OE/HDO 30
(81349) MIL-L-2104
9150-00-186-6681 1 Quart Can QT
9150-00-188-9858 5 Gallon Drum GAL.
9150-00-189-6729 55 Gallon Drum GAL.
33 O LUBRICATING OIL: general purpose,
corrosion resistant and oxidation resistant
(92895) PQRUSTPREVENTIVENO172
9150-00-273-2389 4 Ounce Can OZ
engine, tactical service, OE/HDO 15/40
(81349) MIL-L-2104
9150-01-152-4117 1 Quart Can QT
9150-01-152-4118 5 Gallon Drum GAL.
9150-01-152-4119 55 Gallon Drum GAL.
Change 1 C-5
TM 9-2320-280-20-3

(1) (2) (3) (4) (5)
NATIONAL
ITEM STOCK
35 C PRIMER, ADHESIVE: spray

(81349) MIL-A-46050C
8010-01-826-3535 15 Ounce Can OZ
36 C RAG: wiping, cotton and
cotton-synthetic
(58536) A-A-531
7920-00-205-1711 50 Pound Bale LB
37 O REPAIR KIT, Glass Reinforcement
Plastic Laminate
(81349) MIL-R-19907D
2090-00-372-6064 1 Kit KT
38 O SEALANT: silicone, RTV
(11862) 1052734
6850-01-159-4844 8-1/2 Ounce Tube OZ
39 O SEALING COMPOUND
(05972) 51831
8030-01-374-3504 50 Milliliter Tube ML
8030-01-374-2338 300 Milliliter Cartridge ML
40 O SEALING COMPOUND: adhesive, elastomeric
(00333) M6325-11OZ
41 O SEALING COMPOUND: anaerobic, adhesive/sealant
(05972) 272-40
8030-01-171-7628 50 CC Bottle CC
42 O SEALING COMPOUND: canvas
(81349) MIL-A-46106
8040-01-010-8758 1 Quart QT
43 O SEALING COMPOUND: corrosion-resistant
(81349) MIL-S-81733, type II
8030-00-009-5023 Kit EA
44 O SEALING COMPOUND: pipe,
anaerobic, with teflon
(05972) 59231
8030-01-054-0740 50 Milliliter Tube ML
45 O SEALING COMPOUND:
thread-locking, high strength
(80244) MIL-S-46163, type I, grade K
8030-00-148-9833 10 CC Bottle CC
C-6 Change 1
TM 9-2320-280-20-3

(1) (2) (3) (4) (5)
NATIONAL
ITEM STOCK
46 O SEALING COMPOUND:
thread-locking, medium strength
(80244) MIL-S-46163, type II, grade N
8030-01-025-1692 250 CC Bottle CC
47 O SEALING COMPOUND: windshield
(04963) 847H
8030-00-165-6547 1 Quart Container QT
47.1 O SEALING COMPOUND: electrical
components silicone rubber, clear
(71984) RTV 737
48 O SILICONE COMPOUND: dielectric colloid,
non-melting, heat stable, NATO code no. S-736
(81349) MIL-S-8660
6850-00-880-7616 8 Ounce Tube OZ
6850-00-295-7685 10 Pound Can LB
49 O SODIUM BICARBONATE:
technical (baking soda)
(81348) O-S-576
6810-00-264-6618 1 Pound Box LB
6810-00-290-5574 100 Pound Bag LB
50 O TAPE: pressure-sensitive adhesive,
polyester film, transparent, 1 in. wide, 2 mil thick
(80063) SMA597833-3
7510-00-149-0732 72 Yard Roll YD
51 O TAPE: pressure-sensitive adhesive,
masking, flat, 1 in. width
(19203) 8790710
7510-00-283-0612 60 Yard Roll YD
52 O TAPE: hook and pile material
(81349) MIL-F-211840
8315-01-115-7617 YD
53 O TWINE: fibrous, cotton
(string) 16-ply
(81348) T-T-871
4020-00-291-5901 375 Yard Spool YD
Change 1 C-7/(C-8 blank)

TM 9-2320-280-20-3
APPENDIX D
ILLUSTRATED LIST OF MANUFACTURED ITEMS
D-1. SCOPE
This appendix includes complete instructions for making items authorized to be manufactured or fabricated
at unit maintenance.
D-2. GENERAL
a. A part number index in alphanumeric order is provided for cross-referencing the part number of the
item to be manufactured to the figure which covers fabrication criteria.
b. All bulk materials needed for manufacture of an item are listed by part number or specification number
in a tabular list on the illustration.
Table D-1. Manufactured Items Part Number Index.
PART NO. FIGURE NO. PART NO. FIGURE NO. PART NO. FIGURE NO.
MS51331-1 D-88 5573534 D-35 5584373 D-37
MT161A D-90 5574986 D-21 5584383 D-15
M23053/1-204-0 D-61 5575468 D-24 5584707 D-21
M23053/7-204-2 D-61 5577552 D-35 5584813 D-22
M23053/4-303-0 D-1 5578874 D-39 5584836 D-22
M23053/4-303-2 D-1 5578875 D-39 5584892 D-39
M232053/4-304-2 D-2 5578876 D-39 5584893 D-39
RR-C-271 D-15.1 5578877 D-39 5588617-7.5 D-33
RR-C-271-6 D-3 5578878 D-39 5588618-13 D-32
SF5575898 D-7 5578887 D-9 5588698 D-8
SF5585243 D-16 5578910 D-10 5588767 D-11
SF5585245 D-16 5578911 D-11 5589086 D-29
SF5585258 D-16 5578940 D-30 5589275 D-31
SF5589035 D-4 5578999 D-12 5590023 D-14
SF5589036 D-4 5579007 D-11 5590024 D-14
SF5589037 D-5 5579008 D-10 5590025 D-14
SF5590706 D-26 5579997 D-13 5591157 D-37
SF5591372 D-6 5581213 D-27 5591158 D-37
SF5591612 D-25 5581366 D-34 5591159 D-37
SF5592748 D-4 5582451 D-62 5591161 D-37
12338591-1 D-94 5582479 D-14 5591168 D-37
12342947 D-94 5582641 D-37 5591180 D-15
12446730 D-95 5582642 D-37 5591210 D-36
12446770 D-86 5582643 D-37 5591253 D-37
12446771 D-87 5582645 D-37 5591482 D-37
12446821 D-62.1 5582646 D-37 5591483 D-37
14066306 D-18 5582648 D-15 5591681 D-15
15667 D-91 5582649 D-15 5591707 D-37
15847 D-38 5583183 D-14 5591937 D-14
15848 D-38 5583855 D-15 5591938 D-14
1775-826 D-17 5584173 D-37 5592085 D-58
23500024 D-11 5584188 D-28 5594083 D-36
23500084 D-19 5584372 D-15 5594278 D-23
Change 1 D-1
TM 9-2320-280-20-3
Table D-1. Manufactured Items Part Number Index (Cont’d).
PART NO. FIGURE NO. PART NO. FIGURE NO. PART NO. FIGURE NO.
5595995 D-23 5597995 D-59 5598815 D-54
5597214 D-60 5597997 D-59 5598816 D-45
5597215 D-60 5597998 D-59 5598817 D-46
5597216 D-60 5597999 D-59 5598818 D-48
5597217 D-60 5598000 D-59 5598819 D-41
5597218 D-60 5598029 D-59 5598820 D-47
5597219 D-60 5598030 D-59 5598821 D-53
5597220 D-60 5598031 D-59 5598825 D-63
5597221 D-60 5598032 D-59 5598826 D-63
5597222 D-60 5598033 D-59 5598827 D-64
5597223 D-60 5598034 D-59 5598828 D-65
5597224 D-60 5598035 D-59 5598829 D-66
5597225 D-60 5598036 D-59 5598830 D-67
5597226 D-60 5598061 D-59 5598832 D-68
5597227 D-60 5598062 D-59 5598833 D-69
5597228 D-60 5598063 D-59 5598834 D-70
5597229 D-60 5598064 D-59 5598835 D-71
5597230 D-60 5598065 D-59 5598836 D-72
5597231 D-60 5598132 D-60 5598837 D-73
5597232 D-60 5598133 D-60 5598838 D-74
5597722 D-60 5598134 D-60 5598839 D-75
5597723 D-60 5598236 D-44 5598840 D-76
5597724 D-60 5598237 D-43 5598841 D-77
5597725 D-60 5598238 D-40 5598842 D-78
5597726 D-60 5598239 D-57 5598843 D-79
5597727 D-60 5598240 D-55 5598844 D-80
5597728 D-60 5598241 D-49 5598845 D-81
5597730 D-60 5598242 D-50 5598846 D-82
5597957 D-60 5598243 D-56 5598847 D-83
5597958 D-60 5598245 D-52 5740702 D-10
5597970 D-60 5598813 D-42 8434398 D-114
5597994 D-59 5598814 D-51
D-2 Change 1
TM 9-2320-280-20-3
Section Il. ILLUSTRATED MANUFACTURING INSTRUCTIONS
Figure D-1. Heat Shrink Insulation Sleeving
INSTRUCTIONS:
Cut insulation to length shown.
INSTRUCTIONS:
D-3
TM 9-2320-280-20-3
Section Il. ILLUSTRATED MANUFACTURING INSTRUCTIONS (Cont’d)
Figure D-3. Towing Pintle Lock Chain
lNSTRUCTIONS:
Cut chain to length shown.
Figure D-4. Defroster Flex Ducting
INSTRUCTIONS:
Determine ducting part number needed from RPSTL and cut ducting to length shown.
D-4
TM 9-2320-280-20-3
INSTRUCTIONS:
Cut duct to length shown.
INSTRUCTIONS:
Cut duct to length shown.
D-5
TM 9-2320-280-20-3
Figure D-7. Battery Cable Edge Protector
INSTRUCTIONS:
Cut edge protector to length shown.
Figure D-8. Arctic/Ambulance Heater Fuel Supply Hose
INSTRUCTIONS:
Cut hose to length shown.
D-6
TM 9-2320-280-20-3
Figure D-9 Fuel Can Drain Hose
lNSTRUCTIONS:
Figure D-10. Fuel Supply Hose
INSTRUCTIONS:
Determine hose part number needed from RPSTL and cut hose to length shown.
D-7
TM 9-2320-280-20-3
Section II. ILLUSTRATED MANUFACTURING INSTRUCTIONS (Cont'd)
Figure D-11. Fuel Hose
INSTRUCTIONS:
Figure D-12. Overflow Hose
lNSTRUCTIONS:
D-8
TM 9-2320-280-20-3
Figure D-13. Heater Hose
INSTRUCTIONS:
Figure D-14. Transmission Cooling Lines Connector Hoses and Steering Hydraulic System Hoses
INSTRUCTIONS:
D-9
TM 9-2320-280-20-3
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICATION
0.250 IN. INSIDE DIAMETER HOSE, NONMETALLIC N/A
0.500 IN. OUTSIDE DIAMETER
VENT LINE HOSE PART NUMBER

ITEM HOSE CUT MANUFACTURED
NO. PART NUMBER LENGTH FROM NSN
(INCHES)
1 5582648 4 4720-00-289-9625
2 5582649 25 4720-01-325-0204
3 5583855 42 4720-00-289-9625
4 5584372 8 4720-00-289-9625
5 5584383 32 4720-00-289-9625
6 5591180 2 4720-00-289-9625
7 5591681 18 4720-00-289-9625
Figure D-15. Vent Line Hose.
INSTRUCTIONS:
MATERIAL BLOCK
BULK CHAIN, WELDLESS RR-C-271, TYPE II, CLASS 7-16
FUEL CAP CHAIN

PART NUMBER CUT MANUFACTURED
LENGTH
(INCHES) FROM NSN
RR-C-271 8 4010-00-958-0633
Figure D-15.1. Fuel Cap Chain.
INSTRUCTIONS:
Cut chain to length shown.
D-10 Change 1
TM 9-2320-280-20-3
Figure D-16. Windshield Washer Hose
lNSTRUCTIONS:
Figure D-17. Air Restriction Hose
INSTRUCTIONS:
D-11
TM 9-2320-280-20-3
Figure D-18. Fuel Drain Back Hose
INSTRUCTIONS:
Figure D-19. Thermostat Bypass Hose
INSTRUCTIONS:
D-12
TM 9-2320-280-20-3
Figure D-20. Fuel Drain Back Hose
INSTRUCTIONS:
Figure D-21. Handle Edge Protector
INSTRUCTIONS:
Determine edge protector part number needed from RPSTL and cut edge protector to length shown.
D-13
TM 9-2320-280-20-3
Figure D-22. Fixed Door Seal
INSTRUCTIONS:
Determine seal part number needed from RPSTL and cut seal to length shown.
Figure D-23. Handle Edge Protector
INSTRUCTIONS:
Determine edge protector part number needed from RPSTL and cut edge protector to length shown.
D-14
TM 9-2320-280-20-3
Figure D-24. Anti-Noise Pad
INSTRUCTIONS:
Cut pad to size shown.
Figure D-25. Windshield Lower Seal
INSTRUCTIONS:
Cut seal to length shown.
D-15
TM 9-2320-280-20-3
Section II. ILLUSTRATED MANUFACTURING INSTRUCTIONS (Cont’d)
Figure D-26. Windshield Lower Seal
INSTRUCTIONS:
Figure D-27. Rubber Lower Seal
INSTRUCTIONS:
D-16
TM 9-2320-280-20-3
Figure D-28. Tray Assembly Seal
INSTRUCTIONS:
Figure D-29. Arctic Curtain Seal
INSTRUCTIONS:
D-17
TM 9-2320-280-20-3
Figure D-30. Spiral Wrap Chafe Guard
INSTRUCTIONS:
Cut chafe guard to length shown.
Figure D-31. Foam Insulation Strip
INSTRUCTIONS:
D-18
TM 9-2320-280-20-3
Figure D-32. Run Flat Lube Package Tape
INSTRUCTIONS:
Cut tape to length shown.
D-19
TM 9-2320-280-20-3
Section Il. ILLUSTRATED MANUFACTURING INSTRUCTIONS [Cont’d)
Figure D-33. Filament Tape
INSTRUCTIONS:
Cut tape to length shown,
Figure D-34. Foam Tape
INSTRUCTIONS:
Cut tape to length shown.
D-20
TM 9-2320-280-20-3
Figure D-35. Fuel System Vent Line
INSTRUCTIONS:
Determine vent line part number needed from RPSTL and cut vent line to length shown.
Figure D-36. Fuel Tank Vent Line
INSTRUCTIONS:
Cut vent line to length shown.
D-21
TM 9-2320-280-20-3
Figure D-37. Vent Line Tube
INSTRUCTIONS:
Determine tube part number needed from RPSTL and cut tube to length shown.
D-22
TM 9-2320-280-20-3
Figure D-38. Winch Battery Cable
INSTRUCTIONS:
1. Determine cable number needed from RPSTL and cut cable 6145-00-538-8219 to length as shown.
2. Select and solder proper end terminals to cable ends as shown. (Refer to TM 9-237 for soldering
instructions.)
3. Install insulator as shown.
4. Cut 14 inches of spiral wrap from bulk 25 FT 2661-8P (98441) and install as shown. Spiral wrap is
held in position with black tape at both ends.
5. Mark and install identification band using old cable as reference.
D-23
TM 9-2320-280-20-3
D-24
TM 9-2320-280-20-3
Figure D-39. Battery Cable Assembly
INSTRUCTIONS:
1. Determine cable number needed from RPSTL and cut wire 6154-00-705-6674 to length as shown.
NOTE
Ž Items 1, 4, 5, 6, and 7: flat of terminals to be 90° offset as shown without
wire twist.
Ž Item 6: one terminal end is bent 30°.
instructions.)
NOTE
Insulator boot 5582481 is installed on 30° bent terminal end of item 6.
3. Select and install proper insulators as shown.
4. Mark and install circuit number identification band and part, number identification band using old
cable as reference.
D-25
TM 9-2320-280-20-3
Figure D-40. A/C Compartment Side Front Insulation

INSTRUCTIONS:
Cut insulation to dimensions shown.
D-26
TM 9-2320-280-20-3
Figure D-41. A/C Compartment Passenger Side Ceiling Insulation
INSTRUCTIONS:
D-27
TM 9-2320-280-20-3
Figure D-42. A/C Compartment Bulkhead Outboard Insulation
INSTRUCTIONS:
D-28
TM 9-2320-280-20-3
Figure D-43. A/C Compartment Side Rear Insulation
INSTRUCTIONS:
D-29
TM 9-2320-280-20-3
Figure D-44. A/C Compartment Roof Insulation
INSTRUCTIONS:
D-30
TM 9-2320-280-20-3
Section Il. ILLUSTRATED MANUFACTURING INSTRUCTIONS (Cont'd)
Figure D-45. A/C Compartment Front Closeout Insulation
INSTRUCTIONS:
Figure D-46. A/C Compartment Front Ceiling Insulation
INSTRUCTIONS:
D-31
TM 9-2320-280-20-3
Figure D-47. A/C Compartment Driver Compartment Above Door Insulation
INSTRUCTIONS:
D-32
TM 9-2320-280-20-3
Section Il. ILLUSTRATED MANUFACTURING INSTRUCTIONS (Cont'd)
Figure D-48. A/C Compartment Driver Side Ceiling Insulation
INSTRUCTIONS:
D-33
TM 9-2320-280-20-3
Figure D-49. A/C Compartment Condenser Top Outer Insulation
INSTRUCTIONS:
D-34
TM 9-2320-280-20-3
Figure D-50. A/C Compartment Condenser Top Inner Insulation
INSTRUCTIONS:
D-35
TM 9-2320-280-20-3
Figure D-51. A/C Compartment Bulkhead Upper Inboard Insulation
INSTRUCTIONS:
D-36
TM 9-2320-280-20-3
Figure D-52. A/C Compartment Access Door Insulation
INSTRUCTIONS:
D-37
TM 9-2320-280-20-3
Figure D-53. A/C Compartment Access Door Insulation
INSTRUCTIONS:
D-38
TM 9-2320-280-20-3
Figure D-54. A/C Compartment Condenser Side Inner Insulation
INSTRUCTIONS:
D-39
TM 9-2320-280-20-3
Figure D-55. A/C Compartment Condenser Side Insulation
INSTRUCTIONS:
D-40
TM 9-2320-280-20-3
Figure D-56. A/C Compartment Condenser Closeout Panel Insulation
INSTRUCTIONS:
D-41
TM 9-2320-280-20-3
Figure D-57. A/C Compartment Condenser Side Insulation
INSTRUCTIONS:
D-42
TM 9-2320-280-20-3
Figure D-58. Litter Stowage Door Seal
INSTRUCTIONS:
D-43
TM 9-2320-280-20-3
Figure D-59. NBC Door and Access Panel Seals
lNSTRUCTIONS:
D-44
TM 9-2320-280-20-3
Figure D-60. NBC System PVC Tubing
D-45
TM 9-2320-280-20-3
Figure D-60. NBC System PVC Tubing (Cont‘d)
INSTRUCTIONS:
NOTE
Make sure tubing is cut square at ends, and
ends are free of nicks, burrs, and cracks.
Determine tubing part number needed from RPSTL and cut tube to length shown.
INSTRUCTIONS:
D-46
TM 9-2320-280-20-3
MATERIAL BLOCK
"O" GAGE WIRE, ELECTRICAL MIL-C-13486
200 AMP ALTERNATOR CABLE ASSEMBLY

CABLE CUT LENGTH MANUFACTURED END TERMINAL END INSULATOR
PART NUMBER (INCHES) FROM NSN NSN NSN
5582451 58 6145-00-705-6674 5940-00-735-5520 5970-00-174-9449
Figure D-62. 200 Amp Alternator Cable Assembly.
INSTRUCTIONS:
1. Cut cable to length as shown.
2. Cut 14 inches of spiral wrap from bulk and install as shown. Secure spiral wrap in position with
black tape at both ends.
instructions.)
4. Install insulator and insulator boot to cable ends as shown.
5. Mark and install identification bands using old cable as reference.
Change 1 D-46.1
TM 9-2320-280-20-3
MATERIAL BLOCK
"O" GAGE WIRE, ELECTRICAL MIL-C-13486
12 VOLT ALTERNATOR CABLE ASSEMBLY

CABLE CUT LENGTH MANUFACTURED END TERMINAL END INSULATOR
PART NUMBER (INCHES) FROM P/N PART NUMBER PART NUMBER
12446821 102 M13486/1-9 MS20659-108 12460417
Figure D-62.1. 12 Volt Alternator Cable Assembly.
INSTRUCTIONS:
1. Cut cable to length as shown.
2. Cut of 92.50 inches spiral wrap from bulk and install as shown. Secure spiral wrap in position with
tape at both ends.
instructions.)
4. Install insulator and insulator boot to cable ends as shown.
5. Mark and install identification bands using old cable as reference.
D-46.2 Change 1
TM 9-2320-280-20-3
MATERIAL BLOCK
0.250-IN. DIAMETER TUBE, METALLIC MIL-T-6845
0.250-IN. (NOM)
INSIDE DIAMETER HOSE, NONMETALLIC MIL-H-13444
0.438-IN. (NOM)
OUTSIDE DIAMETER
FUEL FILTER BLEEDER TOOL

CUT
ITEM TOOL LENGTH MANUFACTURED
NO. PART NUMBER (INCHES) FROM NSN
1 5598825 1-1/2 4710-00-825-5894

2 5598826 24 4720-00-542-3304
Figure D-63. Fuel Filter Bleeder Tool.
INSTRUCTIONS:
1. Cut steel tube, NSN 4710-00-825-5894, to length as shown.
2. Thread one end of the tube 5/8 inch.
3. Install nut, NSN 5310-00-997-1888, and O-ring, NSN 5330-00-966-8657, on threaded end of tube.
4. Install 24-inch rubber hose, NSN 4720-00-542-3304, to the other end of the tube.
Change 1 D-47
TM 9-2320-280-20-3
MATERIAL BLOCK
1. .125 IN. THICK FLAT STEEL N/A
2. .375 IN. DIAMETER ROUND STEEL N/A
GLOW PLUG TOOL

ITEM CUT MANUFACTURED FROM
NO. LENGTH PART NUMBER (FSCM)
(INCHES)
1 as shown 9515-00-204-3994
2 as shown 9510-00-189-0652
DIMENSIONS:
A. 7-1/2” F. 11/32”
B. 5-1/2” G. 45°
C. 2” H. 1/8” Flat Steel
D. 1/2” I. 3/8” Rod
E. 3/4”
Figure D-63.1. Glow Plug Tool Assembly.
INSTRUCTIONS:
1. Cut steel to lengths as shown.
2. Weld flat steel and round steel together at angle as shown.
3. Forked end (dimension F) must fit behind hex-head of glow plug. Thickness may have to be ground
down from .125 inch to .0625 inch to insure proper fit.
D-48 Change 1
TM 9-2320-280-20-3
Figure D-64. Plastic Sheet
INSTRUCTIONS:
Cut two pieces of plastic large enough to cover small hole or crack with enough to overlap about 1/4 in.
around damaged area of window.
D-49
TM 9-2320-280-20-3
Figure D-65. Protective Shield

INSTRUCTIONS:
1. Cut aluminum sheet metal to size as shown.

2. Locate, mark, and drill two 0.193-in. diameter holes in protective shield (1).
3. Locate, mark, and drill three 0.203-in. diameter holes in protective shield (1).
4. Make two 0.50-in. relief cuts in sides of protective shield (1).
5. Bend edges (90° bend along dotted lines) on protective shield (1).
6. Remove all burrs and sharp edges.
7. Paint protective shield (1) as required. Refer to TM 43-0139.
D-50
TM 9-2320-280-20-3
Figure D-66. Protective Engine Cover

INSTRUCTIONS:
1. Cut plywood to dimensions shown. If necessary, modify plywood for proper fit.
2. Paint cover and outline with yellow safety boarder, 4-inches wide on outside edges.
3. Stencil “NO STEP AREA” caution on outside edges.
4. Prior to installing protective engine cover, remove both plate covers and seals from airlift brackets.
5. Store flat or hang on wall to prevent warpage.
D-51
TM 9-2320-280-20-3
Figure D-67. Cooler Fin Protective Cover
INSTRUCTIONS:
1. Cut plywood to dimensions shown. If necessary, modify plywood for proper fit.
2. Never use cover with engine running; engine damage will occur.
3. Stencil “NO STEP” caution to top of cover.
4. Prior to installing cooler fin protective cover, remove both plate covers and seals from airlift bracket.
5. Store flat or hang on wall to prevent warpage.
D-52
TM 9-2320-280-20-3
Figure D-68. Siren Mounting Bracket

INSTRUCTIONS:
1. Fabricate siren mounting bracket according to dimensions shown.

3. Clean per SPEC TT-C-490. Treat per SPEC Type I or II, or SPEC TT-C-490.
4. Prime per SPEC MIL-P-52192, MIL-P-53022, or MIL-P-53030.
5. Finish-paint per SPEC MIL-C-46168.
D-53
TM 9-2320-280-20-3
Figure D-69. Warning Light Mounting Bracket

INSTRUCTIONS:
1. Fabricate warning light mounting bracket according to dimensions shown.
2. Weld sizes are minimum. Weld per SPEC MIL-STD-1261.
4. Clean per SPEC TT-C-490. Treat per SPEC Type I or II, or SPEC TT-C-490.
5. Prime per SPEC MIL-P-52192, MIL-P-53022, or MIL-P-53030.
6. Finish-paint per SPEC MIL-C-46168.
D-54
TM 9-2320-280-20-3
Figure D-70. Wire “D” - Adapter “A” to Adapter Connector “B”
Figure D-71. Wire “F" - Passenger Side Siren Switch to Adapter Connector “B”
D-55
TM 9-2320-280-20-3
Figure D-72. Wire “G” – Passenger Side Siren Switch Adapter Connector “E”
Figure D-73. Wire “L” – Relay Lead “C” to Circuit Breaker in Battery Box
D-56
TM 9-2320-280-20-3
Figure D-74. Wire "K" - Battery Ground Stud by Relay Mounting Ground
Figure D-75. Wire "I" - Siren Assembly Mount to Relay Mounting Ground
D-57
TM 9-2320-280-20-3
Figure D-76. Wire “N” – Circuit Breaker to Battery Stud (Positive)
Figure D-77. Wire "H" – Siren Hot Side to Adapter Connector “E” .
D-58
TM 9-2320-280-20-3
Figure D-78. Wire "J" - Warning Light Black Lead to Relay Mounting Ground
Figure D-79. Wire “A” - Light Toggle Switch to Adapter Connector “D”
D-59
TM 9-2320-280-20-3
Figure D-80. Wire “B” - Light Toggle Switch Adapter Connector “A”
Figure D-81. Wire “M” - Warning Light Red Lead to Adapter Connector “D”
D-60
TM 9-2320-280-20-3
Figure D-82. - Relay Connector
D-61
TM 9-2320-280-20-3
lNSTRUCTIONS:
1. Remove cargo shell door strap from vehicle. Refer to para. 11-22.
2. Position grab loop one-third of the way down strap. Fold strap into thirds and mark top fold.
3. Secure grab loop to strap with thread using box stitch and string. Refer to FM 10-16.
4. Install cargo shell door strap on vehicle with grab loop facing the rear. Refer to para. 11-22.
Figure D-83. Grab Loop
D-62
TM 9-2320-280-20-3
Figure D-84. Felt Sheet
INSTRUCTIONS:
Cut felt to dimensions shown.
D-63
TM 9-2320-280-20-3
Figure D-85. Heat Shield Extension
INSTRUCTIONS:
All inside bend radius to 6.12 unless otherwise specified.
D-64
TM 9-2320-280-20-3
MATERIAL BLOCK
STOCK SIZE DESCRIPTION SPECIFICIATION
10 X 12-FT SHEET. ALUMINUM ALLOY IAW QQ-A-225/8

0.08 IN. THICK 6061-T6
LEFT SPLASH SHIELD ACCESS COVER

ACCESS COVER CUT TO SIZE MANUFACTURED FROM
PART NUMBER (INCHES) NSN
12446770 AS SHOWN 9530-01-071-2140
Figure D-86. Left Splash Shield Access Cover.
INSTRUCTIONS:
2. Locate, mark, and drill two .313-.375-in. diameter holes in left splash shield access cover as shown.
3. Locate, mark, and drill one .406-.466-in. diameter hole in left splash shield access cover as shown.
5. Paint left splash shield access cover as required. (Refer to TM 43-0139.)
Change 1 D-65
TM 9-2320-280-20-3
LEFT SPLASH SHIELD

SPLASH SHIELD CUT MANUFACTURED FROM
PART NUMBER (INCHES) PART NUMBER
12446771 AS SHOWN 12340361
Figure D-87. Left Splash Shield.
INSTRUCTIONS:
1. Remove left splash shield. (Refer to para. 10-17.)
2. Cut hole (2) in left splash shield (1) as shown.
3. Using fabricated access cover (6) as a template, locate, mark, and drill a 0.312-inch diameter hole (5)
through left splash shield (1) as shown.
NOTE
Existing mounting hardware is used to secure bottom right-hand hole.
4. Secure top two holes of access cover (6) to left splash shield (1) with two NSN 5306-00-225-8499
washers (4), NSN 5306-00-225-8499 screws (7), NSN 5310-00-087-7493 washers (4), and
NSN 5310-00-814-0673 nuts (3) as shown.
5. Install modified left splash shield. (Refer to para. 10-17.)
D-66 Change 1
TM 9-2320-280-20-3
Figure D-88. Mud Flap.
INSTRUCTIONS:
2. Locate, mark, and drill two .75 X .40 in. slots in mud flap plate.
3. Locate, mark, and drill two .40 in. diameter holes in mud flap plate.
5. Locate, mark, and drill eight holes in angle bracket (5) as shown.
6. Paint as required. Refer to TM 43-0139.
7. Install mud flap (1) between mounting bracket (2) and angle bracket plate (5) with four washers (3),
D-67
TM 9-2320-280-20-3
Figure D-89. “C” Pillar Reinforcement Bracket.
lNSTRUCTIONS:
1. Cut two pieces of aluminum sheet metal to size as shown.
2. Locate, mark, and drill four 0.125-inch diameter holes in reinforcement brackets (1).
3. Bend left reinforcement bracket (1).
4. Bend right reinforcement bracket (1) in opposite direction.
D-68
TM 9-2320-280-20-3
Figure D-90. Turret Bearing Seal.
INSTRUCTIONS:
1. Cut seal to length shown.
D-69
TM 9-2320-280-20-3
Figure D-91, Winch Wire Rope Assembly
INSTRUCTIONS:
1. (a) Properly seize wire rope end before cutting. To seize wire rope end, follow these instructions.
NOTE
Ž Ensure each wrap is tight to the preceding wrap.
Ž Ensure the length of the seizing is not less than the diameter
of the wire rope.
(1) Wrap the seizing wire around the wire rope as tight as possible.
(2) Twist the ends of the seizing together by hand counterclockwise so that the twist is near the
middle of the seizing.
NOTE
Do not try to tighten the seizing by twisting.
(3) Tighten the twist just enough to take up the slack.

(4) Tighten the seizing by prying the twist away from the axis of the wire rope.
(5) Tighten the twist again as described in step (3).
(6) Repeat the process until the seizing can not be pryed away from the axis of the wire rope.
(7) Cut off wire ends and pound the twist into contact with the seizing.
(b) Cut wire rope to length as shown and install part of clamp with nut on wire rope.
D-70
TM 9-2320-280-20-3

2. Position rope after seizing in a suitable fixture to make a loop, leaving enough rope to wrap around
thimble and enclose in clamp.
3. Thread wire rope through eyelid in hook, insert thimble and close jaws of fixture to enable rope to
conform to groove of thimble.
4. Place one half of clamp in position and adjust rope accordingly. The seized portion of the wire rope
should equal one rope diameter and protrude entirely beyond the threaded end of the clamp half.
5. Install clamp nut. Holding both threaded halves in position, push the nut into both halves through
the first two threads. Ensure proper alignment of both threaded halves, and that there is no cross-
threading.
6. Remove rope, clamp and thimble while still connected.
7. Hold opposing flats of clamp halves in suitable fixture and properly lubricate exposed threads with
high-viscosity lubricating oil.
8. Using a permanent marker, mark one flat nut to ensure the same opposing flats are checked before
and after tightening the clamp.
9. Using calipers, measure 1/8 inch across the flat nut from the bottom and note measurement.
10. Check to make sure clamp halves are properly secured in fixture, and tighten with appropriate
wrench.
11. Using calipers, again take measurement of the same flat nuts as was done before tightening of the
nut. If the increment dilation is between 0.004 and 0.007 inches, clamp is tight.
12. Using arbor press, crimp terminal to opposite end of wire rope.
Change 1 D-71
TM 9-2320-280-20-3
Figure D-92. Ambulance Bulkhead Door Retainer.

lNSTRUCTIONS:
1. Cut retainer to length shown.
D-72
TM 9-2320-280-20-3
Figure D-93. Parking Brake Lever.

INSTRUCTIONS:
CAUTION
When drilling through the transmission cowl, be careful not to drill
into the transmission housing.
NOTE
The location of the mounting hole will vary depending on vehicle
configuration. Locate the hole in a suitable place, near the driver’s
seat
1. Drill a 1/4-in. hole in the transmission cowl (7), near the driver’s seat (10).
2. Cut chain (4) to desired length and install the clamp (1) on chain (4) with capscrew (5), lockwasher (2),
and nut (3).
3. Install chain (4) on transmission cowl (7) with capscrew (6), lockwasher (9), and nut (8).
4. With the parking brake applied, slip clamp (1) over lever (11) to lock it in place. When not in use, stow
the chain lock out of the way.
5 Paint chain lock red for easy identification.
D-73
TM 9-2320-280-20-3
INSTRUCTIONS:
1. Disconnect battery ground cable (Refer to para. 4-73).
NOTE
Have container availabe to catch fluid drainage from hydraulic
hoses.
2. Remove clamp (4) and hydraulic hose (5) from elbow fitting (2).
3. Disconnect fan drive hydraulic hose (11) from fitting (12).
4. Remove elbow fitting (2) from adapter bushing (9).
5. Remove nut (3), washer (6), and washer (8) securing adapter bushing (9) to fan shroud (7).
6. Remove fan drive hydraulic hose (11) from elbow fitting (10).
7. Remove fitting (12) from fan drive (1).
NOTE
Apply sealing compound (appendix C, item 44) to all pipe threads
during installation.
8. Install hose (13) on elbow fitting (10).
9. Install quick-disconnect (14) on fitting (15).
10. Install fan drive hydraulic hose (13) in quick-disconnect (14).
11. Install fitting (15) in fan drive (1).
12. Install adapter bushing (9) and washer (8) in fan shroud (7) with washer (6) and nut (3).
13. Install elbow fitting (2) in adapter bushing (9).
14. Install hydraulic hose (5) on elbow fitting (2) with clamp (4).
16. Bleed power steering system (para. 8-29).
D-74
TM 9-2320-280-20-3
Figure D-94. Fan Drive Quick-Disconnect.
D-75
TM 9-2320-280-20-3
lNSTRUCTlONS:
1. Using existing turret handle (1) as a template, scribe two reference lines (2) on weapon station (4).
2. Locate and mark the center of six spot welds (3) on turret handle (1).
NOTE
Ensure drill does not penetrate weapon station.
3. Using 0.313-inch diameter drill bit, drill out six spot welds (3) in turret handle (1).
4. Using chisel, remove turret handle (1) from weapon station (4).
NOTE
When grinding weapon station, ensure that the two reference lines
are not removed.
5. Grind off any remaining spot weld (3) material flush with weapon station (4).
6. Using two reference lines (2) marked in step 1, position turret handle (5) on weapon station (4).
7. Using turret handle (5) as a template, drill four 0.344-inch diameter holes (6) in weapon station (4).
8. Spot paint weapon station (4) (refer to TM 43-0139).
9. Install turret handle (5) on weapon station (4) with four washers (8), capscrews (7), washers (8), and
locknuts (9).
10. Spot paint capscrews (7) and locknuts (9) (refer to TM 43-0139).
D-76
TM 9-2320-280-20-3
Figure D-95. Turret Handle Replacement.
D-77
TM 9-2320-280-20-3
MATERIAL BLOCK
14 AWG WIRE, ELECTRICAL MIL-C-13486
N/A INSULATION SLEEVING MIL-I-23053/2
ITEM MATERIALS
NO. REQ’D DESCRIPTION NSN/PART NUMBER
1 8 Insulation Sleeving: 2 in. 5970-01-815-1295
2 8 Electrical Wire: 48 in. 6145-00-152-6499
3 8 Wire Marker 46F5981
4 5 Tiedown Strap 5975-00-074-2072
5 1 Receptacle 5935-00-738-8328
Figure D-96. Body Harness Receptacle Fabrication.

INSTRUCTIONS:
NOTE
When connecting electrical wire to connector pins on engine
harness plug connector, use NSN 3439-00-133-1108 solder. (Refer
to TB SIG-222 for soldering.)
1. Cut eight sections of wire (2) to length as shown.
2. Cut eight sections of insulation sleeving (1) as shown.
3. Position eight sections of insulation sleeving (1) on wires (2).
4. Connect eight sections of wire (2) to receptacle pins marked A, B, C, D, E, F, G, and H on recep-
tacle (5). Place insulation sleeving (1) over wires (2) and receptacle pins and into position as shown.
5. Apply sealant NSN 8040-00-225-4918 to receptacle pins, wires, and sleeving.
6. Use wire markers (3) on eight sections of wire (2) to locate and mark wires. Secure eight sections of
wire (2) with five tiedown straps (4).
D-78 Change 1
TM 9-2320-280-20-3
MATERIAL BLOCK
ITEM MATERIALS
1 1 Grommet 5365-00-772-2322
4 5 Tiedown Strap 5975-00-074-2072
5 1 Grommet Retaining Nut 5935-00-333-9414
6 1 Coupling Nut 5310-00-655-9860
7 1 Plug Shell Assembly 5935-00-686-2608
Figure D-97. Body Harness Connector Fabrication.

INSTRUCTIONS:
NOTE
When connecting electrical wires to connector pins on body harness
connector, use NSN 3439-00-133-1108 solder. (Refer to TB SIG-222
for soldering.)
1. Cut eight sections of wire (2) to length as shown.
2. Place grommet retaining nut (5) over eight sections of wire (2).
3. Position eight sections of wire (2) in grommet (1).
4. Place coupling nut (6) over plug shell assembly (7).
5. Connect eight sections of wire (2) to receptacle pins marked A, B, C, D, E, F, G, and H on plug shell
assembly (7).
6. Position grommet (1) in plug shell assembly (7) and secure with grommet retaining nut (5).
7. Use wire markers (3) on eight sections of wire (2) to locate and mark wires. Secure eight sections of
wire (2) with five tiedown straps (4).
Change 1 D-79
TM 9-2320-280-20-3
MATERIAL BLOCK
8 AWG WIRE, ELECTRICAL MIL-C-13486/1
ITEM MATERIALS
1 1 Plug Connector 5935-01-173-7654
4 6 Tiedown Strap 5975-00-074-2072
5 1 Coupling Nut 5310-00-655-9860
Figure D-98. Engine Harness Plug Connector Fabrication.
D-80 Change 1
TM 9-2320-280-20-3
INSTRUCTIONS:
NOTE
harness plug connector, use NSN 3439-00-133-1108 solder. (Refer
to TB SIG-222 for soldering.)
1. Cut three sections of electrical wire (6) to length as shown.

2. Remove 3-in. (76.2 mm) section of electrical insulation from electrical wire (6).
3. Cut three sections of insulation sleeving (7) to length as shown.
4. Position three sections of insulation sleeving (7) over wires (6).
5. Using plug connector (1), disassemble shell, coupling nut (5), ferrule, and grommet.
6. Place coupling nut (5) and ferrule over three wires (6).
7. Place three wires (6) in holes marked D, E, and F in grommet.
8. Connect three wires (6) to receptacle pins marked D, E, and F on shell.
9. Cut six sections of electrical wire (2) to length as shown.
10. Place six wires (2) in coupling nut (5), ferrule, and holes marked A, B, C, G, H, and I on grommet.
11. Connect six wires (2) to receptacle pins marked A, B, C, G, H, and I on shell.
12. Position grommet and ferrule in shell and secure with coupling nut (5). Using three wires (6) with
insulation, heat-shrink sleeving (7) in position.
13. Apply sealant NSN 8040-00-225-4918 to three wires (6) and insulation sleeving (7) on plug
connector (1).
14. Using plug connector (1) and wire markers (3), locate and mark nine wires. Secure nine wires with
six tiedown straps (4).
Change 1 D-81
TM 9-2320-280-20-3
MATERIAL BLOCK
ITEM MATERIALS
1 3 Insulation Sleeving: 1-1/2 in. (38.1 mm) 5970-00-812-2967
2 3 Electrical Wire: 60 in. (1,524 mm) 6145-00-538-8222
4 6 Tiedown Strap 5975-00-074-2072
5 6 Electrical Wire: 60 in. (1,524 mm) 6145-00-152-6499
6 6 Insulation Sleeving: 1-1/2 in. (38.1 mm) 5970-00-815-1295
7 1 Receptacle Connector 5935-01-149-5163
Figure D-99. Engine Harness Receptacle Fabrication.
D-82 Change 1
TM 9-2320-280-20-3
INSTRUCTIONS:
NOT E
harness receptacle, use NSN 3439-00-133-1108 solder. (Refer to
TB SIG-222 for soldering.)
1. Cut three sections of electrical wire (2) to length as shown.
2. Cut three sections insulation sleeving (1) to length as shown.
3. Position three sections of insulation sleeving (1) on wires (2).
4. Connect three wires (2) to receptacle pins marked D, E, and F on receptacle connector (7). Place
insulation sleeving (1) over wires (2) and receptacle pins and heat-shrink insulation sleeving (1) into
position.
5. Apply sealant NSN 8040-00-225-4918 to three wires (2) and insulation sleeving (1) on receptacle
connector (7).
6. Cut six sections of electrical wire (5) to length as shown.
7. Cut six sections of insulation sleeving (6) to length as shown.
8. Position six sections of insulation sleeving (6) on wires (5).
9. Connect six wires (5) to receptacle pins marked A, B, C, G, H, and I on receptacle connector (7).
Place electrical insulating sleeving (6) over wires (5) and receptacle pins and heat-shrink insulation
sleeving (6) into position.
10. Use wire markers (3) on nine sections of wire to locate and mark wires. Secure wires with six
tiedown straps (4).
Change 1 D-83
TM 9-2320-280-20-3
ITEM MATERIALS
4 1 Mini-box (bottom section) 5999-00-971-8848
7 6 Screw 5305-00-958-4353
8 6 Washer 5310-00-880-5976
9 6 Non-metallic Bumper 5340-01-219-6733
10 6 Nut 5310-00-934-9753
Figure D-100. Mini-box Bottom Section Drill Procedure.
D-84 Change 1
TM 9-2320-280-20-3
Figure D-100. Mini-box Bottom Section Drill Procedure (Cont’d).
INSTRUCTIONS:
1. Locate, mark, and drill 0.138-in. diameter hole (1) in mini-box bottom section (4) as shown.
2. Locate, mark, and drill two 1.250-in. diameter holes (2) in mini-box bottom section (4) as shown.
3. Locate, mark, and drill four 0.190-in. diameter holes (3) in mini-box bottom section (4) as shown.
4. Locate, mark, and drill fourteen 0.138-in. diameter holes (5) in mini-box bottom section (4) as shown.
5. Locate, mark, and drill two 0.750-in. diameter holes (6) in mini-box bottom section (4) as shown.
6. Install six non-metallic bumpers (9) on mount holes on mini-box bottom section (4) with washers (8),
screws (7), and nuts (10) as shown.
Change 1 D-85
TM 9-2320-280-20-3
MATERIAL BLOCK
3 ft CHANNEL N/A
PRE-PUNCHED CHANNEL
CHANNEL MANUFACTURED
CUT LENGTH
PART NUMBER FROM NSN
67 AS SHOWN N/A
Figure D-101. Pre-punched Channel.
INSTRUCTIONS:
Cut two channels to length shown.
D-86 Change 1
TM 9-2320-280-20-3
ITEM MATERIALS
NO. REQ’D DESCRIPTION PART NUMBER
1 1 Channel, Pre-punched: 7 in. 67
2 6 Terminal Block 0621
4 1 End Section 0630
5 2 Channel Clamp 68
Figure D-102. Channel, 7.00-in. and Terminal Block Assembly.
INSTRUCTIONS:
Install three terminal blocks (2), terminal blocks (3), terminal blocks (2), and end section (4) on
channel (1) with two channel clamps (5).
Change 1 D-87
TM 9-2320-280-20-3
ITEM MATERIALS
NO. REQ’D DESCRIPTION PART NUMBER
1 1 Channel, Pre-punched: 6 in. 67
3 1 End Section 0630
4 2 Channel Clamp 68
Figure D-103. Channel, 6.00-in. and Terminal Block Assembly.
INSTRUCTIONS:
Install eight terminal blocks (2) and end section (3) on channel (1) with two channel clamps (4).
D-88 Change 1
TM 9-2320-280-20-3
ITEM MATERIALS
1 2 Grommet, Non-metallic 5325-00-270-8890
2 4 Cable Tie Holder MB4A
3 8 Screw 5305-00-958-4353
4 4 Screw 5305-00-984-6210
5 1 Mini-box (bottom section) 5999-00-971-8848
6 2 Grommet, Non-metallic 5325-00-309-7164
8 4 Nut 5310-00-934-9758
9 4 Washer 5310-00-883-9384
10 8 Washer 5310-00-880-5976
11 8 Nut 5310-00-934-9753
Figure D-104. Terminal Block Assemblies and Cable Tie Holder Installation.
INSTRUCTIONS:
1. Using wire marker (7) and 6-in. and 7-in. terminal block assemblies, locate and mark sections as
shown.
2. Install 6-in.and 7-in. terminal block assemblies in mini-box bottom section (5) with four screws (4),
3. Install four cable tie holders (2) in mini-box bottom section (5) with eight screws (3), washers (10), and
nuts (11).
4. Install two non-metallic grommets (1) in holes A on mini-box bottom section (5).
5. Install two non-metallic grommets (6) in holes B on mini-box bottom section (5).
Change 1 D-89
TM 9-2320-280-20-3
MATERIAL BLOCK
ITEM MATERIALS
1 16 Receptacle Pin 1-87756-6
4 11 Terminal Lug 5940-00-577-3807
5 1 Receptacle Plug 103308-8
Figure D-105. Receptacle Plug and Pin Assemblies.
D-90 Change 1
TM 9-2320-280-20-3
Figure D-105. Receptacle Plug and Pin Assemblies (Cont’d).
INSTRUCTIONS:
1. Cut fourteen sections of electrical wire (2) to length as shown.
2. Install fourteen receptacle pins (1) on wires (2) as shown.
3. Using fourteen wire markers, mark wires (2) with numbers 1 through 13 and 16 as shown.
4. Install eleven terminal lugs (4) on wires (2) marked 2, 3, 4, 5, 6, 7, 9, 10, 12, 13, and 16 as shown.
5. Install two receptacle pins (1) (without wires) in slotted positions marked 14 and 15 on receptacle
plug (5).
6. Install fourteen receptacle pins (1) (with wires connected) in slotted positions marked 1, 2, 3, 4, 5, 6, 7,
8, 9, 10, 11, 12, 13, and 16 on receptacle plug (5).
Change 1 D-91
TM 9-2320-280-20-3
ITEM MATERIALS
NO. REQ’D DESCRIPTION NSN
3 28 Terminal Lug 5940-00-283-5280
INSTRUCTIONS:
NOTE
• Ensure wire markers match letter identification for connector
and receptacle harness assemblies.
• Trim excess wire to required length when installing wire and
terminal lugs to terminal block assembly.
1. Route wires (5) from body harness receptacle (6) through grommet (7).
2. Install eight terminal lugs (3) on wires (5) from body harness receptacle (6).
3. Install wires (5) marked A, B, C, D, E, F, G, and H on body harness receptacle (6) to matching letters
on terminal block assembly (4).
4. Route wires (10) from body harness connector (8) through grommet (9).
5. Install eight terminal lugs (3) on wires (10) from body harness connector (8).
6. Install wires (10) marked A, B, C, D, E, F, G, and H on body harness connector (8) to matching
letters on terminal block assembly (4).
7. Route wires (13) on engine harness connector (14) through grommet (15).
8. Connect three wires (12) marked D, E, and F on engine harness connector (14) to matching letters
on terminal block assembly (11). Do not tighten screws.
9. Install six terminal lugs (3) on wires (13) from engine harness connector (14)
10. Install wires (13) marked A, B, C, G, H, and I on engine harness connector (14) to matching letters
on terminal block assembly (11).
11. Route wires (2) on engine harness receptacle (1) through grommet (16).
12. Connect three wires (12) marked D, E, and F on engine harness receptacle (1) to matching letters on
terminal block assembly (11).
13. Install six terminal lugs (3) on wires (2) from engine harness receptacle (1).
14. Install wires (2) marked A, B, C, G, H, and I on engine harness receptacle (1) to matching letters on
terminal block assembly (11).
D-92 Change 1
TM 9-2320-280-20-3
Figure D-106. Body, Engine Harness Connector, and Receptacle Installation.
Change 1 D-93
TM 9-2320-280-20-3
Figure D-107. Receptacle Plug Installation.

INSTRUCTIONS:
NOTE
• Ensure wire markers match letter identification for connector
and receptacle harness assemblies.
• Trim excess wire to required length when installing wire and
terminal lugs to terminal block assembly.
1. Connect wires (3) marked 2, 3, 4, 6, 7, and 16 on receptacle plug (4) to terminal strip (2) marked H, F,
G, C, D, and B.
2. Connect wire (3) marked 13 on receptacle plug (4) to terminal strip (2) marked E.
3. Connect wires (5) marked 1, 8, 11 on receptacle plug (4) to terminal strip (1) marked E, F, D.
4. Connect wires (3) marked 5, 9, 10, and 12 on receptacle plug (4) to terminal strip (1) marked A, H, I,
and G.
D-94 Change 1
TM 9-2320-280-20-3
ITEM MATERIALS
3 4 Screw 5305-00-984-6210
4 2 Loop Clamp 5340-00-057-2904
5 2 Conduit Insulation: 48 in. 68240
6 AR Tape 7510-00-802-8311
8 4 Washer 5310-00-883-9384
9 4 Nut 5310-00-934-9758
11 4 Tiedown Strap 5975-00-074-2072
12 2 Loop Clamp 5434-00-724-7038
13 2 Conduit Insulation: 54 in. 68243
Figure D-108. Terminal Strip Installation.
INSTRUCTIONS:
1. Install four tiedown straps (11) in cable tie holders (10) and secure wires (2) to cable tie holders (10)
with tiedown straps (11).
2. Install two loop clamps (4) on wires (2) of body harness connector and receptacle with screws (3),
3. Install two loop clamps (12) on wires (2) of engine harness connector and receptacle with screws (3),
4. Cut two 48-in. (1,219.2 mm) sections of conduit insulation (5).
5. Remove ten tiedown straps (7) from wires (2) of body harness connector and receptacle.
6. Position two sections of conduit insulation (5) over wires (2) of body harness connector and receptacle
and secure with tape (6).
7. Cut two 54-in. (1,371.6 mm) sections of conduit insulation (13).
8. Remove twelve tiedown straps (7) from wires on engine harness connector and receptacle.
9. Position sections of conduit insulation (13) over wires (2) on engine harness connector and receptacle
and secure with tape (6).
Change 1 D-95
TM 9-2320-280-20-3
MATERIAL BLOCK
ITEM MATERIALS
2 5 Tip Jack 5935-00-683-7651
Figure D-109. Tip Jack Lead Assembly.
INSTRUCTIONS:
NOT E
When connecting electrical wire to receptacle pins on tip
jacks, use NSN 3493-00-133-1108 solder. (Refer to TB SIG-222
for soldering.)
1. Cut wire (1) into five 12-in. sections as shown.

2. Cut insulation sleeving (3) into five 1-in. sections as shown.
3. Connect five wires (1) to receptacle pins on tip jacks (2).
4. Place insulation sleeving (3) over wires (1) and receptacle pins and heat-shrink insulation sleeving (3)
into position.
D-96 Change 1
TM 9-2320-280-20-3
Figure D-110. Mini-box Top Section Drill Procedure.
INSTRUCTIONS:
1. Locate, mark, and drill thirteen 0.156-in. diameter holes (1) in mini-box top section (4).
2. Locate, mark, and drill six 0.205-in. diameter holes (3) in mini-box top section (4).
3. Locate, mark, and drill four 0.138-in. diameter holes (2) in mini-box top section (4).
Change 1 D-97
TM 9-2320-280-20-3
ITEM MATERIALS
1 Data Mark Set 7510-01-040-7110
1 Data Mark Set 7510-01-158-1037
2 13 Led 5980-01-288-0188
3 1 Mini-Box (top section) 5999-00-971-8848
4 5 Tip Jack (assembled in figure D-109) 5935-00-683-7651
7 5 Terminal Lug 5940-00-283-5280
10 1 Tip Jack 5935-00-683-7651
Figure D-110. Mini-box Top Section Drill Procedure (Cont’d).

INSTRUCTIONS (CONT’D):
4. Using data mark set, mark location of thirteen holes (1) on mini-box top section (3).
5. Using data mark set, mark location of six holes (9) on mini-box top section (3).
6. Install tip jack (10) and nut (8) in hole (9) marked 2 on mini-box top section (3).
7. Install five tip jacks (4) with wires (5) and nuts (6) in holes (9) marked 1, 3, 4, 5, and 6 on mini-box
top section (3).
8. Install five terminal lugs (7) to wires (5) on tip jacks (4).
9. Install thirteen LEDs (2) in holes (1) marked 1 through 13 on mini-box top section (3).
10. Cut electrical insulation sleeving (13) into twenty-five sections as shown.
11. Place twelve sections of electrical insulation sleeving (13) over red (+) wires (11) marked 2, 3, 4, 5, 6,
7, 8, 9, 10, 11, 12, and 13 on LEDs (2).
12. Place thirteen sections of electrical insulation sleeving (13) over black (–) wires (12) marked 1, 2, 3,
4, 5, 6, 7, 8, 9, 10, 11, 12, and 13 on LEDs (2).
D-98 Change 1
TM 9-2320-280-20-3
MATERIAL BLOCK
N/A WIRE, ELECTRICAL MIL-W-16878/4
N/A PUNCH BOARD 64P44EP
ITEM MATERIALS
1 1 Punch Board: 2 x 3 in. 64P44EP
Figure D-111. Punch Board and Electrical Wire.
INSTRUCTIONS:
1. Cut punch board (1) to size as shown.
2. Locate, mark, and drill four 0.375-in. diameter holes in punch board (1) as shown.
3. Cut thirty-one 5-in. sections of electrical wire (2) as shown.
Change 1 D-99
TM 9-2320-280-20-3
ITEM MATERIALS
1 1 Plug Connector 5935-01-230-9304
2 1 Punch Board (fabricated in figure D-99) 64P44EP
3 1 Isolated Resistor Network 13F170
4-6 3 Diode ECG125
7 1 Bussed Resistor Network 13F171
31 Wire (cut in figure D-99)
Figure D-112. Punch Board Assembly.
INSTRUCTIONS:
1. Install plug connector (1) on punch board (2).
2. Install fourteen wires to pins (8) marked 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, and 16 on plug
connector (1).
3. Install insulated resistor network (3) on punch board (2).
4. Install six wires to pins (8) marked 1, 4, 7, 8, 11, and 14 on isolated resistor network (3).
5. Install bussed resistor network (7) on punch board (2).
6. Install eleven wires to pins (8) marked 1, 2, 3, 4, 5, 8, 9, 10, 11, 12, and 14 on bussed resistor
network (7).
7. Install diodes (4), (5), and (6) on punch board (2).
D-100 Change 1
TM 9-2320-280-20-3
Figure D-113. Test Module Assembly.
INSTRUCTIONS:
1. Connect wire marked 6 on plug connector to banded end of diode R1.
2. Connect wire marked 14 on isolated resistor network to bandless end of diode R1.
3. Connect wire marked 7 on plug connector and wire marked 14 on bussed resistor network to banded
end of diode R2.
4. Connect wire marked 13 on plug connector to bandless end of diode R3.
5. Connect wire marked 11 on isolated resistor network to bandless end of diode R2.
6. Connect wire marked 8 on isolated resistor network bandless end of diode R3.
7. Connect wire marked 1 on isolated resistor network to black (-) wire marked 6 on LED on mini-box
top section.
8. Connect wire marked 4 on isolated resistor network to black (-) wire marked 7 on LED.
9. Connect wire marked 7 on isolated resistor network to black (-) wire marked 13 on LED.
Change 1 D-101
TM 9-2320-280-20-3
Figure D-113. Test Module Assembly (Cont’d).
10. Connect wire marked 16 on plug connector to red (+) wire marked 13 on LED.
11. Connect wire marked 1 on plug connector to three red (+) wires marked 1, 6, and 7 on LED.
D-102 Change 1
TM 9-2320-280-20-3
Change 1 D-103
TM 9-2320-280-20-3
21. Connect wire marked 1 on bussed resistor network to black (–) wire marked 1 on LED.
D-104 Change 1
TM 9-2320-280-20-3
ITEM MATERIALS
2 4 Spacer 313-1437-024
3 25 Insulation Sleeving (install in figure D-110) 5970-00-812-2974
4 4 Screw 5305-00-928-9021
8 4 Washer 5310-00-880-5976
9 4 Nut 5310-00-934-9753
31. Place electrical insulation sleeving (3) over wire (10) marked 1 on plug connector.
32. Place twenty-four sections of insulation sleeving (3) over connected wires (6) and (11) on LEDs (5) and
heat-shrink into position.
33. Install four screws (4) in mount holes (12) on mini-box top section (1) and position four spacers (2) and
punch board (7) on screws (4) and secure with four washers (8) and nuts (9).
Change 1 D-105
TM 9-2320-280-20-3
MATERIAL BLOCK
14 AWG WIRE ELECTRICAL MIL-C-13486/1
ITEM MATERIALS
1 2 Terminal Lug 5940-00-577-3807
7 1 Screw 5305-00-984-6210
8 1 Nut 5310-00-934-9758
11 1 Washer 5310-00-883-9384
D-106 Change 1
TM 9-2320-280-20-3
34. Cut electrical wire (2) to length as shown.
35. Connect two terminal lugs (1) on wire (2).
36. Install wire (2) and tip jack lead (3) marked 5 on mount hole (10) on mini-box bottom section (9) with
washer (11), screw (7), and nut (8).
37. Connect wire (2) to terminal strip (4) marked D with screw (5).
38. Connect tip jack lead (3) marked 1 to terminal strip (6) marked H with screw (5).
39. Connect tip jack lead (3) marked 3 to terminal strip (6) marked B with screw (5).
40. Connect tip jack lead (3) marked 4 to terminal strip (6) marked C with screw (5).
41. Connect tip jack lead (3) marked 6 to terminal strip (6) marked A with screw (5).
42. Using existing drive pin, punch out four screw mount holes (14) in mini-box top section (12).
43. Install plug (16) and connector (15) as shown.
44. Install mini-box top (12) on bottom section (9) with four existing screws (13).
Change 1 D-107
TM 9-2320-280-20-3
MATERIAL BLOCK
39.00 IN. MINIMUM CLOTH,COATED PLASTIC, 11 TYPE AND 2 CLASS
VINYL BOTH SIDES
GREEN RUBBER CANVAS

PART CUT MANUFACTURED
NO. LENGTH FROM NSN
(INCHES)
8434398 2 at 3X12 8305-00-616-0022
4 at 4X15
2 at 36X6
39.00
Figure D-114. Green Rubber Canvas Straps.
INSTRUCTIONS:
1. Cut canvas, NSN 8305-00-616-0022, into eight reinforcement straps for lengths shown.
2. Secure six grommets, NSN 5325-00-281-8643, and six stud turn buttons, NSN 5325-00-930-7607, to
canvas straps using twelve clinch plate turn buttons, NSN 5325-00-371-8108.
D-108 Change 1
TM 9-2320-280-20-3
MATERIAL BLOCK
0.188 IN. THICK STRIP, METAL ASTM-A569
HEX WRENCH
NO. LENGTH FROM NSN
(INCHES)
N/A as shown 9515-00-814-7316
2.375
HEX
0.31R 6PL
3.000 Ø
0.50R 2PL
10.000
0.188
0.12R 2PL
1.250
Figure D-115. Hex Wrench.
INSTRUCTIONS:
1. Cut piece of steel sheet metal to size as shown.

Change 1 D-109
TM 9-2320-280-20-3
MATERIAL BLOCK
0.125 IN. THICK STRIP, METAL ASTM-A569
0.188 IN. THICK
OPEN END WRENCHS

NO. LENGTH FROM NSN
(INCHES)
N/A as shown 9515-00-814-7316
9515-00-596-2044
Figure D-116. Open End Wrench.
INSTRUCTIONS:
1. Cut piece of 0.188 in. steel sheet metal to make handle (2) as shown.
2. Cut two 0.125 in. pieces of sheet metal to make two jaws (1) as shown.
3. Weld two jaws (1) to handle (2).
D-110 Change 1
TM 9-2320-280-20-3
MATERIAL BLOCK
0.700 IN. THICK ALUMINUM ALLOY N/A
SHEET
NO. LENGTH FROM NSN
(INCHES)
N/A as shown 9530-00-226-0380
Figure D-117. Fixture Fabrication.
INSTRUCTIONS:
1. Fabricate fixture according to dimensions as shown.

Change 1 D-111
TM 9-2320-280-20-3
MATERIAL BLOCK
N/A BAR, METAL ASTM A108
SHEET
NO. LENGTH FROM NSN
(INCHES)
N/A as shown 9510-00-229-4822
Figure D-118. Bushing Fabrication.
INSTRUCTIONS:
1. Using NSN 9510-00-229-4822 metal bar, fabricate bushing (1) as shown.

3. Press bushing (1) into fixture hole (2) (fixture fabricated in figure D-117).
D-112 Change 1
TM 9-2320-280-20-3
MATERIAL BLOCK
0.375 IN. INSIDE DIAMETER HOSE, WIRE BRAIDED N/A
0.625 IN. OUTSIDE DIAMETER
ITEM MATERIALS
AR Sealing Compound 8030-01-054-0740
1 1 Adapter, Straight Swivel 4730-00-547-0941
2 1 Adapter, Straight 4730-01-309-0949
3 2 Clamp, Hose 4730-00-024-3971
5 1 Adapter, Straight 4730-00-140-3770
6 1 Coupling, Pipe 4730-01-071-2859
7 1 Nipple, Pipe 4730-00-193-2709
Figure D-119. Hose.
INSTRUCTIONS:
NOT E
Do not apply sealing compound to first two threads of straight
adapter.
1. Connect clamp (3), straight adapter (2), and straight swivel adapter (1) to hose (4). Tighten clamp (3).
2. Connect clamp (3), straight adapter (5), pipe coupling (6), and pipe nipple (7) to hose (4). Tighten
clamp (3).
Change 1 D-113
TM 9-2320-280-20-3
MATERIAL BLOCK
0.125 X 2.57 X 3.50 IN. ALUMINUM FLAT SHEET IAW ASTM B 209
0.125 X 0.75 X 24.0 IN. ALUMINUM RECTANGLE IAW ASTM B 211
.50 .125
2.07
2.57
.50
3.50
.75
.125 24.0
Figure D-120. Pulley Alignment Tool Fabrication.
INSTRUCTIONS:
NOT E
• Remove all burrs and sharp edges from aluminum sheet
and rectangle.
• Pulley alignment tool can be assembled using nuts, bolts,

rivets, or by welding.
1. Cut aluminum sheet (1) to size as shown.

2. Position aluminum rectangle (2) on top of aluminum sheet (1) as shown in figure D-130.
NOT E
Check all measurements before welding, riveting, or bolting
pulley alignment tool together.
3. Assemble pulley alignment tool as shown in figure D-130.
D-114 Change 1
TM 9-2320-280-20-3
24.0
0.12
2PL
1.370
1.870±.005 OPTIONAL
.75 ASSEMBLY
USING WELDING
.5
0.12
2PL
1.320±.005
OPTIONAL ASSEMBLY
DRILLING HOLES
AND USING NUTS,
BOLTS, OR RIVETS
Figure D-120. Pulley Alignment Tool Fabrication (Cont’d).
Change 1 D-115
TM 9-2320-280-20-3
MATERIAL BLOCK
WIRE, ELECTRICAL
18 AWG MIL-C-13486
(WITH INSULATION)
ITEM MATERIALS
1 1 Terminal Lug 5940-00-113-8184
2 1 Terminal Lug 5940-00-504-4703
3 1 Electrical Wire: 9.7 in. 6145-00-570-0516
9.70 in.
Figure D-121. Grounding Jumper Wire.
INSTRUCTIONS:
1. Cut a electrical wire (3) to length as shown.
2. Install terminal lugs (1) and (2) as shown.
D-116 Change 1
TM 9-2320-280-20-3
APPENDIX E
TORQUE LIMITS
E-1. GENERAL
This section provides general torque limits for screws used on the M998 series vehicles. Special torque limits
are indicated in the maintenance procedures for applicable components. The general torque limits given in
this appendix shall be used when specific torque limits are not indicated in the maintenance procedure.
Unless otherwise specified, standard torque tolerance shall be ± 10%. These general torque limits cannot be
applied to screws that retain rubber components. The rubber components will be damaged before the correct
torque limit is reached. If a special torque limit is not given in the maintenance instructions, tighten the
screw or nut until it touches the metal bracket, then tighten it one more turn.
E-2. TORQUE LIMITS
Table E-1 lists dry torque limits. Dry torque limits are used on screws that do not have lubricants applied to
the threads. Table E-2 lists wet torque limits. Wet torque limits are used on screws that have high pressure
lubricants applied to the threads.
E-3. HOW TO USE TORQUE TABLE
c. Under the heading SIZE, look down the left-hand

column until you find the diameter of the screw you
are installing (there will usually be two lines
beginning with the same size).
d. In the second column under SIZE, find the number
of threads per inch that matches the number of
threads you counted in step b.
CAPSCREW HEAD MARKINGS

Manufacturer’s marks may vary.
These are all SAE Grade 5
(3-line).
a. Measure the diameter of the screw
you are installing.
e. To find the grade screw you are installing, match

the markings on the head to the correct picture of
CAPSCREW HEAD MARKINGS on the torque
table.
f. Look down the column under the picture you found
in step e. until you find the torque limit (in lb-ft or
NŽm) for the diameter and threads per inch of the
screw you are installing.
b. Count the number of threads

per inch.
E-1
TM 9-2320-280-20-3
Table E-1. Torque Limits for Dry Fasteners
E-2
TM 9-2320-280-20-3
Table E-2. Torque Limits for Wet Fasteners
E-3
TM 9-2320-280-20-3
APPENDIX E (Cont’d)
E-5. CONVERSION FORMULA
Corrected dial or scale readings are determined by the use of the following formula:
NOTE
The length of the torque wrench is
measured from the center of the handle
to the center of the drive. The length of
the adapter is measured from the center
of the drive to the center of the winch.
Example:
In this example, the torque wrench measures 22 in. (55.9 cm) and the adapter is 3 in. (7.6 cm). The
required torque is 19 lb-ft (25.8 NŽm).
E-4
TM 9-2320-280-20-3
APPENDIX F
WIRING DIAGRAMS AND SCHEMATIC
F-1. GENERAL
This appendix contains wiring diagrams of special vehicle equipment and an overall vehicle electrical
system schematic you will need to maintain M998 series vehicles.
F-2. WIRING DIAGRAM AND SCHEMATIC INDEX
FIGURE PAGE
TITLES
NO. NO.
F-1 Winch Wiring Diagram F-2

F-2 Arctic Winterization Kit Wiring Diagram F-3
F-3 AN/GRC-160 Communications Kit Wiring Diagram F-4
F-4 Slave Receptacle and TOW Harness Wiring Diagram F-5
F-5 M1097, “A1”, and “A2” Series Vehicles, Switch and F-6
Lamp Transfer Case Low Lock Indicator Wiring Diagram
F-6 M1097, “A1”, and “A2” Series Vehicles, Auxiliary Power Supply Wiring Diagram F-7
F-7 Siren and Warning Light Wiring Diagram F-8
F-8 Glow Plug Control Functional Logic Diagram F-9
F-9 Protective Control Box (“A2” Series Vehicles) F-10
F-10 Buss Bar and 12 Volt Transmission Power (“A2” Series Vehicles) F-11
FO-1 Electrical System Wiring Diagram FP-1
FO-2 Electrical System Wiring Diagram (M996 and M996A1) FP-3
FO-3 Electrical System Wiring Diagram (M997 and M997A1) FP-7
FO-4 Electrical System Wiring Diagram (M1025A2, M1035A2, M1043A2, and M1045A2) FP-11
FO-5 Electrical System Wiring Diagram (M1097A2) FP-13
FO-6 Electrical System Wiring Diagram (M997A2) FP-15
Change 1 F-1
TM 9-2320-280-20-3
Figure 1. Winch Wiring Diagram.
F-2
TM 9-2320-280-20-3
Figure 2. Arctic Winterization Kit Wiring Diagram.
F-3
TM 9-2320-280-20-3
Figure 3. AN/GRC-160 Communications Kit Wiring Diagram.
F-4
TM 9-2320-280-20-3
The following applies to vehicles with serial number 100,000 and above and vehicles with kits 5705623 and
5705624 installed.
Figure 4. Slave Receptacle and TOW Harness Wiring Diagram.
F-5
TM 9-2320-280-20-3
Figure F-5. M1097, “A1”, and “A2” Series Vehicles, Switch and Lamp
Transfer Case Low Lock Indicator Wiring Diagram.
F-6
TM 9-2320-280-20-3
Figure F-6. M1097, “A1”, and “A2” Series Vehicles, Auxiliary

Power Supply Wiring Diagram.
F-7
TM 9-2320-280-20-3
Figure F-7. Siren and Warning Light Wiring Diagram.
F-8
TM 9-2320-280-20-3
Figure F-8. Glow Plug Control Functional Logic Diagram.
F-9
TM 9-2320-280-20-3
Figure F-9. Protective Control Box ("A2" Series Vehicles).
F-10
TM 9-2320-280-20-3
Figure F-10. Buss Bar & 12 Volt Transmission Power ("A2" Series Vehicles).
F-11
TM 9-2320-280-20-3
Figure FO-1. Electrical System Wiring Diagram

(Located at Back of Manual).
F-12
TM 9-2320-280-20-3
APPENDIX G
MANDATORY REPLACEMENT PARTS
G-1. SCOPE
This appendix lists mandatory replacement parts you will need to maintain M998 series vehicles.
G-2. EXPLANATION OF COLUMNS
a. Column (1) - Item Number. This number is assigned to each entry in the listing and is referenced
in the “Initial Setup” of applicable tasks under the heading of “Materials/Parts”.
b. Column (2) - Nomenclature. Name or identification of the part.
c. Column (3) - Part Number. The manufacturer’s part number.
d. Column (4) - National Stock Number. The national stock number of the part.
G-1
TM 9-2320-280-20-3
Section II. MANDATORY REPLACEMENT PARTS

(1) (2) (3) (4)
ITEM PART NATIONAL/NATO
NO NOMENCLATURE NUMBER STOCK NUMBER
1 Access Cover Gasket 12338585 5330-01-194-0473
2 Adapter Seal MS28775-236 5330-00-579-6861
3 Balance Weights 5595966 6670-01-261-6844
4 Bezel Screw MS90728-7 5305-00-225-3840
5 Bolt 12340845-2 5306-01-263-8889
6 Boot Service Kit 5740260 (fixed) 2530-01-191-8741
5740259 (plunged) 2530-01-191-8740
57K0275 (fixed) 2530-01-394-6168
(M1097 and
“A1” series)
57K0274 (plunged) 2530-01-394-3748
239007 “A2” series
(plunged)
2890020 “A2” series
(boot)
2990054 “A2” series
(shaft, fixed, L.H.)
2990055 “A2” series
(shaft, fixed, R.H.)
7 Bushing 12L18F 3120-00-485-1017
8 Capscrew ZAMG9423557 5306-01-300-0420
8.1 Capscrew 12342499-1 5305-01-259-6322
9 Capscrew MS35764-851 5306-01-203-2637
10 Capscrew 5589067 5306-01-204-2139
11 Capscrew 5597349 5306-01-276-1621
11.1 Capscrew 12339413 5306-01-301-0523
12 Center Parts Kit CPL6R30 2520-00-352-2168
13 Clip MS16633-1050 5365-00-442-5845
13.1 Clip MS3215-1050 5325-01-116-9577
14 Clip 354-310300-00 5325-01-257-0001
14.1 Clip 12338868 5325-01-197-3460
15 Copper Washer 5582366 5310-01-189-8476
16 Cotter Pin 137137 5315-00-013-7137
17 Cotter Pin MS24665-283 5315-00-842-3044
17.1 Cotter Pin MS24665-377 5315-00-285-7161
18 Cotter Pin MS24665-355 5315-00-012-0123
19 Cotter Pin 137195 5315-00-012-0123
20 Cotter Pin PK379 5315-00-013-7171
21 Cotter Pin MS24665-134 5315-00-187-9370
G-2 Change 1
TM 9-2320-280-20-3
Section II. MANDATORY REPLACEMENT PARTS (Cont’d)

(1) (2) (3) (4)
22 Cotter Pin MS24665-628 5315-00-846-0126
23 Cotter Pin MS24665-298 5315-00-234-1861
24 Cotter Pin 137185 5315-00-839-5822
25 Cotter Pin MS24665-132 5315-00-839-2325
26 Cotter Pin MS24665-285 5315-00-005-0442
27 Cotter Pin 137946 5315-00-187-9538
27.1 Cotter Pin G121224 5313-01-206-7135
27.2 Cotter Pin 121223 5315-01-839-5820
28 Cotter Pin MS9245-71 5315-00-939-0835
28.1 Distribution Box 12379863 6110-01-446-7125
29 Door Seal R-451-N 5330-01-041-9721
30 Drive Screw MS21318-47 5305-00-253-5626
31 Dust Cap 211121X 5340-01-188-1017
32 Filter Assembly 6437741 2940-01-121-6350
33 Filter Element Kit SA910044 4330-01-198-7590
34 Flat Washer MS27183-20 5310-00-068-5285
35 Fuel Pump Gasket 9776705 5330-01-112-1533
36 Gasket 12338382 5330-01-246-1822
37 Gasket 12338339 5330-01-200-0466
38 Gasket 12338342 5330-01-189-9738
39 Gasket 12342104 5330-01-314-6781
40 Gasket 12342105 5330-01-315-1609
41 Gasket 10137490
42 Gasket 14028951 5330-01-149-0874
43 Gasket 7539072 5330-00-753-9072
44 Gasket DC8226 5330-01-076-6172
45 Gasket 61-2028-01 5330-01-218-1196
46 Gasket 8655625 5330-01-148-7492
47 Gasket 5597942 5330-01-298-8126
48 Gasket 12341487 5330-01-272-7471
49 Gasket 12339414 5330-01-194-0472
50 Gasket 10137488 5330-01-149-0874
51 Gasket 12356789 5330-01-319-7302
51.1 Gasket 12339409 5330-01-184-6500
52 Gasket, Oil Pan OS30442A 5330-01-310-6780
52.1 Gasket, Water Pump 10137492 5330-01-149-9808
52.2 Grommet 426687 5325-00-281-8643
53 Hitch Pin 34403-35-1 5315-01-188-4490
54 Hex Nut 7063812 5310-00-126-3842
Change 1 G-3
TM 9-2320-280-20-3

(1) (2) (3) (4)
55 Input Seal 2994-2106 5330-01-180-9099
56 Journal and Bearing Kit 5-213 2520-01-189-2135
57 Lining, Friction 4026-38368-01 2930-01-189-8643
58 Locknut MS51943-31 5310-00-061-4650
58.1 Locknut 9419471 5310-01-432-6727
58.2 Locknut MS21044C3 5310-00-208-9255
59 Locknut MS21245-L10 5310-00-449-2381
60 Locknut 5593048 (front) 5310-01-252-0481
5592999 (rear) 5310-01-253-0058
61 Locknut 83320 5815-00-126-8238
62 Locknut 5593035 5310-01-255-2695
63 Locknut MS27183-10 5310-00-809-4058
64 Locknut MS51943-32 5310-00-935-9022
65 Locknut MS51943-33 5310-00-814-0673
66 Locknut MS51943-43 5310-00-061-4651
67 Locknut INX59NTE1614 5310-01-192-5759
68 Locknut 3978901 5310-01-021-9027
69 Locknut NAS1408A6 5310-00-316-6513
70 Locknut MS51943-39 5310-00-488-3889
71 Locknut MS21245-8 5310-00-449-2376
72 Locknut MS51967-6 5310-00-931-8167
73 Locknut MS21044-N4 5310-00-877-5796
74 Locknut MS35649-202 5310-00-934-9758
75 Locknut 5584711 5310-01-198-3487
76 Locknut MS51943-34 5310-00-241-6658
77 Locknut 12339730 5310-01-254-4284
78 Locknut 5584710 2510-01-203-3217
79 Locknut MS51943-45 5310-00-409-3333
80 Locknut 5591514 5310-01-217-0715
81 Locknut 5591513 5310-01-265-8968
82 Locknut NAS1022-N08 5310-00-721-5447
83 Locknut MS21083-N08 5310-00-941-6019
84 DELETED
85 Locknut MS21045-7 5310-00-274-9364
86 Locknut MS90728-6 5305-00-068-0508
87 Locknut 5590556 5310-01-208-5252
88 Locknut 454748 5310-01-038-9579
89 Locknut 131245 5310-00-013-1245
90 Locknut 9411893 5310-00-251-4503
G-4 Change 1
TM 9-2320-280-20-3

(1) (2) (3) (4)
91 Locknut 12339501 5310-01-198-7585
92 Locknut 89325 5310-01-212-2215
93 Locknut 274209 5310-00-420-9713
94 Locknut MS21044-N3 5310-00-877-5797
94.1 Locknut 454749 5310-00-164-1790
95 Locknut 454750 5310-00-483-8791
96 Locknut 192481 5310-01-058-3353
97 Locknut 190171 5310-00-774-9073
98 Locknut 9419454 5310-01-066-6759
99 Locknut 9419456 5310-01-318-5237
100 Locknut 272739 5310-01-317-8164
101 Locknut 190139 5310-00-088-0553
102 Locknut MS51922-1 5310-00-088-1251
103 Locknut MS51922-9 5310-00-984-3806
104 Locknut 9419454 5310-01-133-7215
105 Locknut 9411507 5310-01-381-1471
105.1 Locknut MS51943-3 5310-00-472-2963
106 Locknut MS51943-35 5310-00-935-9021
107 Locknut MS51967-18 5310-00-763-8919
107.1 Locknut 11508382 5310-01-206-5479
107.2 Locknut MS17829-4F 5310-00-483-8791
108 Lockwasher MS35338-46 5310-00-637-9541
109 Lockwasher MS35338-45 5310-00-407-9566
110 Lockwasher MS35338-44 5310-00-582-5965
111 Lockwasher MS35338-42 5310-00-045-3299
112 Lockwasher MS51415-9 5310-01-216-7390
113 Lockwasher MS35338-43 5310-00-045-3296
114 Lockwasher 120217 5310-00-922-2017
114.1 Lockwasher MS35336-53 5310-00-957-2677
115 Lockwasher 85031 5310-01-186-7066
116 Lockwasher ERNA245 5310-00-584-5272
117 Lockwasher 2434 5310-00-775-5139
118 Lockwasher MS35338-41 5310-00-045-4007
119 Lockwasher MS45904-60 5310-00-080-9786
119.1 Lockwasher 1500177 5310-01-185-7218
120 Lockwasher MS35338-65 5310-00-011-5093
121 Lockwasher 5584462 5310-01-213-4185
122 Lockwasher MS35338-50 5310-00-820-6653
123 Lockwasher 5592927 5310-01-253-8957
Change 1 G-5
TM 9-2320-280-20-3

(1) (2) (3) (4)
124 Lockwasher MS35333-40 5310-00-550-1130
125 Lockwasher MS45904-68 5310-00-889-2528
126 Lockwasher MS35338-63 5310-00-274-8715
127 Lockwasher MS35338-48 5310-00-584-5272
128 Lockwasher QR816 5310-00-007-1607
129 Lockwasher MS51848-13 5310-01-016-9348
130 Lockwasher AN8013-2 5310-00-167-0893
131 Lockwasher 202755 5310-01-270-2661
132 Lockwasher MS35340-43 5310-00-721-7809
133 Lockwasher 36896 5310-01-162-9661
134 Lockwasher N9018 5310-01-032-4827
135 Lockwasher N9459 5310-01-348-8393
136 Lockwasher N9461 5310-01-348-8392
137 Lockwasher N9015 5310-01-046-0186
138 Lockwasher MS35338-47 5310-00-209-0965
139 Lockwasher MS35335-33 5310-00-209-0786
140 Lockwasher MS35338-26 5310-00-012-0124
140.1 Lockwasher 120384 5310-00-272-4113
140.2 Lockwasher 11500207 5310-01-206-7306
140.3 Lockwasher 5550554 5310-01-144-2779
140.4 Lockwasher 120382 5310-00-012-0283
141 Lubricant Packets 89307-2 2640-01-262-9517
141.1 Lubricant 6004832 2640-01-419-6200
141.2 Lubricant 12460308
142 Mounting Plate Gasket 3705044 5330-00-830-1745
143 Nut 7063812 5310-00-126-3842
144 Nut and Lockwasher Assembly 5593033 5310-01-252-2999
144.1 Nut and Lockwasher Assembly 5592958
145 Nut and Lockwasher Assembly 511-120800-00 5310-00-995-4130
149 Nut and Lockwasher Assembly AN365-1024A 5310-00-208-1918
150 Nut and Lockwasher Assembly 12339998-13 4931-01-202-8692
152 Nylon Washer 5597347 5310-01-259-7554
153 Oil Filter PH13 2940-00-082-6034
154 O-Ring Seal 274244 5330-00-935-9136
155 O-Ring Seal MS28775-020 5330-00-585-7723
G-6 Change 1
TM 9-2320-280-20-3

(1) (2) (3) (4)
156 O-Ring Seal 60018
157 O-Ring Seal 12267802 5330-01-080-3253
158 O-Ring Seal 2-113N497-70 5330-01-184-6492
159 O-Ring Seal 129 5330-01-195-8889
160 O-Ring Seal 12339498 5330-01-176-0923
160.1 O-Ring Seal 12342933
161 O-Ring Seal 2-011N674-70 5330-00-580-6586
162 O-Ring Seal 12338998 5330-01-216-7392
163 O-Ring Seal 5935457 5330-01-335-8878
163.1 O-Ring Seal 12342633 5330-02-335-8878
164 O-Ring Seal 10475299
164.1 O-Ring Seal 5584527 5331-00-580-6586
165 O-Ring Seal 8658110 5330-01-043-5572
165.1 O-Ring, Insert 12342794 5330-01-346-3806
166 Packing 11639519-1 5330-00-463-0200
167 Packing 11639519-2 5330-00-462-0907
167.1 Set, Pinion Setting Gauge 57K3229 5180-01-363-8079
168 Platenuts MS51941-10 5310-01-025-6444
169 Pushnut C183-012 5310-01-213-1333
170 Pushnut 4001714-B 5310-01-188-6861
171 DELETED
172 Retaining Ring 5100-62-S-ZD 5365-00-803-7305
173 Retaining Ring 5741098 5365-01-212-2403
174 Retaining Ring MS16633-1050 5365-00-422-5845
175 Retaining Ring A9036 5365-01-135-4290
176 Retaining Ring 11505885 5365-01-196-5631
176.1 Retaining Strap 12339154
177 Rivet AD44BS 5320-01-123-2529
177.1 Rivet AF3213-6-2 5320-01-143-5075
178 Rivet BALM-6BP-14 5320-01-254-2283
179 Rivet CR-213-4-2 5320-01-258-2576
180 Rivet CR-3242-6-2 5320-01-033-8643
181 Rivet CR-213-4-4 5320-01-220-0596
182 Rivet 5593050 5320-01-254-4251
183 Rivet MS20470AD6-1 5320-00-117-6856
184 Rivet CR-213-6-8 5320-01-273-4601
185 Rivet AD42BS 5320-00-899-0981
186 Rivet CR3-213-6-4 5320-01-136-1782
187 Rivet MS20470AD6-7 5320-00-754-0992
Change 1 G-7
TM 9-2320-280-20-3

(1) (2) (3) (4)
188 Rivet 12339355-1 5320-01-271-6357
189 Rivet MGLP-B6-7 5320-01-264-5978
190 Rivet 5597013 5320-01-272-7486
191 Rivet MS20426-AD6-9 5320-00-117-7289
192 Rivet MS20470AD6-10 5320-00-721-9062
193 Rivet 9401034 5320-01-272-8348
194 Rivet CR-213-4-5 5320-01-259-7423
195 Rivet M24243/3-B404 5320-01-011-9717
195.1 Rivet M24243/1-A403 5320-00-083-5009
196 Rivet M24243/1-A404 5320-01-023-2529
197 Rivet M24243/1-A408 5320-00-850-3282
198 Rivet, 5/32-in. Blind AB5-6 5320-00-850-3267
199 Rivet, 3/16-in. Blind AB6-6 5320-00-962-4693
200 Rivet M7885/6-6-05 5320-01-034-1884
200.1 Rivet 12339737 5325-01-191-7555
201 Rivet M7885/2-6-3-03 5320-01-135-7319
202 Rivet MS27130-A55 5310-00-810-0901
202.1 Rivet 5597598 5320-01-275-1998
203 Rubber Washer 5577895 5310-01-185-7214
204 Rubber Washer 12339052 5310-01-185-7214
204.1 Rubber Washer 12447149
205 Runflat Belt Repair Kit J-39295 2530-01-338-3056
206 Runflat Belt Repair Kit 528240 4310-01-345-5723
207 Screw MS51958-64 5305-00-059-3660
208 Screw 160046 5305-00-068-0508
209 Screw MS51957-45 5305-00-054-6670
210 Screw-Assembled Lockwasher 5593006 5305-01-256-0406
211 Screw-Assembled Lockwasher 5593313 5305-01-254-2459
212 DELETED
213 Seal 14022683 (6.2L) 5330-01-150-7744
23502587 (6.5L)
214 Seal 29940-2094 5330-01-203-6551
215 Seal 5741141 5330-01-211-1343
216 Seal 12340585 5310-01-203-9187
217 Seal 12342886 5330-01-381-1810
218 Seal 12340088 5330-01-202-8360
219 Seal 7700242 5330-00-770-0242
220 Seal 12342343 5330-01-318-1998
221 Seal 12342344 5330-01-318-9780
G-8 Change 1
TM 9-2320-280-20-3

(1) (2) (3) (4)
222 Seal 12342345 5330-01-317-5393
223 Seal 12342248 5330-01-317-5392
224 Seal MT161A 5330-01-282-2213
225 Seal, Washer 4210973 5310-01-260-4847
226 Seal 6002591
227 Seal, Turret 12446768
228 Sound Dampener 5591150 2540-01-192-9716
229 Sound Dampener 5591149 2540-01-192-5948
230 Spacer Plate, 0.125-in. (3.2mm) 5584299 5365-01-197-9383
231 Spacer Plate, 0.060-in. (1.5mm) 12339379 5365-01-253-8980
232 Spacer Plate, Hinge 5584436 5365-01-201-4749
233 Spring Pin MS16562-256 5315-00-844-3665
234 Spring Pin NAS561C4-18 5315-00-559-7467
235 Spring Washer 0625-0225 5310-01-203-3238
236 Spring Washer 4004616 5310-01-189-8485
237 Spring 2-300.P5 5360-01-282-9316
238 Thermaseal 12275161 2540-01-123-1218
239 Tiedown Strap MS3367-3-9 5975-00-451-5001
240 Tiedown Strap 5972090 5340-01-205-5379
241 Tiedown Strap MS3367-3-0 5975-00-985-6630
241.1 Tiedown Strap MS3367-7-0 5975-01-034-5871
242 Tiedown Strap MS3367-1-0 5975-00-984-6582
242.1 Tiedown Strap MS3367-4-0 5975-00-903-2248
242.2 Tiedown Strap MS3367-7-9 5975-00-570-9598
243 Tiedown Strap MS3367-5-0 5975-00-133-8687
243.1 Tiedown Strap MS3367-1-9 5975-00-074-2072
243.2 Turn Button, Fastener BS78505 5325-00-371-8108
Cinch Plate
243.3 Turn Button, Fastener, Stud XB78322 5325-00-930-7607
244 Wellnut S10P175 5310-01-198-1723
245 Woodruff Key MS35756-8 5315-00-616-5526
Change 1 G-9/(G-10 blank)

TM 9-2320-280-20-3
INDEX VOLUME III

Para Page Para Page
A
AB-652/GR antenna: Alternator, 100 ampere (12342944):
Installation . . . . . . . . . . . . . . . . . . . . 12-139b 12-213 Installation. . . . . . . . . . . . . . . . . . . . . 12-24b 12-34
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-139a 12-213 Removal. . . . . . . . . . . . . . . . . . . . . . . . 12-24a 12-32
Accessory kits: Alternator and regulator, 100/200
Installation task summary . . . . . 12-184 12-282 ampere, dual voltage conversion:
Air cleaner dust cap: 100 ampere dual voltage alternator
Inspection. . . . . . . . . . . . . . . . . . 12-6b 12-8 and regulator installation . . . . . . . 12-24.1b 12-34.2
Installation . . . . . . . . . . . . . . . . . . . . 12-6c 12-8 200 ampere dual voltage alternator
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-6a 12-8 and regulator installation . . . . . . . 12-24.1c 12-34.6
Air cleaner extension elbow: Part fabrication . . . . . . . . . . . . . . . . 12-24.1a 12-34.2
Inspection . . . . . . . . . . . . . . . . . . . . . 12-4b 12-6 Alternator cable (12446821-2),
Installation . . . . . . . . . . . . . . . . . . . . 12-4c 12-6 100 ampere
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-4a 12-5 Installation. . . . . . . . . . . . . . . . . 12-22.1b 12-28.2
Air cleaner to selector valve Removal . . . . . . . . . . . . . . . . . . . 12-22.1a 12-28.2
vent line:
Alternator kit, 100 ampere:
Installation . . . . . . . . . . . . . . . . . . . . 12-7b 12-9
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-7a 12-9 Maintenance task summary . . . . 12-20 12-23
Air-conditioning duct louver: Alternator regulator (R027096300):
Installation . . . . . . . . . . . . . . . . . . . . 11-203b 11-308 Installation . . . . . . . . . . . . . . . . . . . . 12-21b 12-26
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-203a 11-308 Removal . . . . . . . . . . . . . . . . . . . . . . . 12-21a 12-24
Air-conditioning/heat duct: Ambulance body:
Assembly . . . . . . . . . . . . . . . . . . . . . . 11-211c 11-320 Maintenance task summary . . . . 11-123 11-173
Disassembly . . . . . . . . . . . . . . . . . . . 11-211b 11-319 Ambulance compartment mat:
Installation . . . . . . . . . . . . . . . . . . . . 11-211d 11-320 Installation . . . . . . . . . . . . . . . . . . . . 11-153b 11-222
Air diverter: Ambulance litter assembly, soft top:
Installation . . . . . . . . . . . . . . . . . . . . 11-213b 11-323 Assembly . . . . . . . . . . . . . . . . . . . . . . 11-124d 11-180
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-213a 11-323 Disassembly . . . . . . . . . . . . . . . . . . . 11-124b 11-178
Air duct assembly: Inspection . . . . . . . . . . . . . . . . . . . . . 11-124c 11-178
Installation . . . . . . . . . . . . . . . . . . . . 10-97b 10-165 Installation . . . . . . . . . . . . . . . . . . . . 11-124e 11-182
Air inlet/outlet grille: Ambulance spreader bar repair:
Installation . . . . . . . . . . . . . . . . . . . . 11-186b 11-270 Assembly . . . . . . . . . . . . . . . . . . . . . . 11-215c 11-325
Air intake assembly, deep Installation . . . . . . . . . . . . . . . . . . . . 11-215d 11-325
water fording kit: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-215a 11-325
Installation . . . . . . . . . . . . . . . . . . . . 12-3b 12-4 Ambulatory patient seat:
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-3a 12-4 Installation . . . . . . . . . . . . . . . . . . . . 11-181b 11-264
Air intake compartment panels: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-181a 11-263
Installation . . . . . . . . . . . . . . . . . . . . 11-184b 11-268 Ambulatory patient seat
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-184a 11-268 rear close out panel:
Air intake duct door:
Installation . . . . . . . . . . . . . . . . . . . . 11-182b 11-265
Installation . . . . . . . . . . . . . . . . . . . . 11-185b 11-269
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-182a 11-265
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-185a 11-269
Air intake filter: Ammo box tray
Cleaning . . . . . . . . . . . . . . . . . . . . . . . 11-205b 11-310 (40 mm and caliber .50):
Inspection . . . . . . . . . . . . . . . . . . . . . 11-205a 11-310 Installation . . . . . . . . . . . . . . . . . . . . 11-105b 11-147
Airlift bracket to hood seal: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-105a 11-147
Installation . . . . . . . . . . . . . . . . . . . . 10-65b 10-104 Ammo box tray (40 mm), double:
Air line piping, NBC: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-106a 11-148
Fabrication . . . . . . . . . . . . . . . . . . . . 11-166b 11-244 Ammo box tray (40 mm), triple:
Installation . . . . . . . . . . . . . . . . . . . . 11-166c 11-244 Installation . . . . . . . . . . . . . . . . . . . . 11-107b 11-149
Alternator, 100 ampere (12340912): Ammo box tray (caliber .50):
Change 1 INDEX 1
TM 9-2320-280-20-3
INDEX (Cont’d)
Para Page Para Page
A (Cont’d)
Ammo box tray (caliber .50), Antenna tower, rear radio rack:
double: Assembly . . . . . . . . . . . . . . . . . . . . . . 12-145c 12-228
Installation . . . . . . . . . . . . . . . . . . . . 11-103b 11-145 Disassembly . . . . . . . . . . . . . . . . . . . 12-145b 12-228
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-103a 11-145 Installation . . . . . . . . . . . . . . . . . . . . 12-145d 12-228
Ammo container, mortar: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-145a 12-228
Assembly . . . . . . . . . . . . . . . . . . . . . . 12-149c 12-238 Antiskid strip:
Disassembly . . . . . . . . . . . . . . . . . . . 12-149b 12-237 Installation . . . . . . . . . . . . . . . . . . . . 12-191b 12-316
Installation . . . . . . . . . . . . . . . . . . . . 12-149d 12-239 Removal . . . . . . . . . . . . . . . . . . . . . . . 12-191a 12-316
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-149a 12-236 “A” pillar, former assembly:
Ammo divider (L119): Installation . . . . . . . . . . . . . . . . . . . . 10-98b 10-167
Installation . . . . . . . . . . . . . . . . . . . . 12-174b 12-267
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-98a 10-167
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-174a 12-267
Ammo rack assembly, M16: Appendix A:
Installation . . . . . . . . . . . . . . . . . . . . 11-74b 11-106 References . . . . . . . . . . . . . . . . . . . . . A-1
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-74a 11-106 Appendix B:
Ammo rack (L119): Maintenance allocation chart. . . B-1
Assembly . . . . . . . . . . . . . . . . . . . . . . 12-181c 12-275 Appendix C:
Disassembly . . . . . . . . . . . . . . . . . . . 12-181b 12-275 Expendable/durable supplies
Installation . . . . . . . . . . . . . . . . . . . . 12-181d 12-276 and materials list . . . . . . . . . . . . . C-1
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-181a 12-274 Appendix D:
Ammo tiedown strap (L119): Illustrated list of
Installation . . . . . . . . . . . . . . . . . . . . 12-173b 12-266 manufactured items. . . . . . . . . . . D-1
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-173a 12-266 Appendix E:
Antenna, AB-652/GR: Torque limits. . . . . . . . . . . . . . . . . . . E-1
Installation . . . . . . . . . . . . . . . . . . . . 12-139b 12-213 Appendix F:
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-139a 12-213 Wiring diagrams and schematic. . F-1
Antenna, AS 1729/VRC: Appendix G:
Installation . . . . . . . . . . . . . . . . . . . . 12-137b 12-211 Mandatory replacement parts . . G-1
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-137a 12-211 Arctic curtain angle assembly:
Antenna blast shield:
Antenna cables, rear: Arctic curtain assembly:
Antenna cables, rear radio Arctic curtain channel assembly
rack to tower: (2-man crew):
Antenna ground strap: Arctic curtain channel assembly
Installation . . . . . . . . . . . . . . . . . . . . 12-136b 12-210 (4-man crew):
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-136a 12-209 Inspection . . . . . . . . . . . . . . . . . . . . . 12-77b 12-110
Antenna mount (M996, M996A1), Installation . . . . . . . . . . . . . . . . . . . . 12-77c 12-110
radio: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-77a 12-110
Installation . . . . . . . . . . . . . . . . . . . . 11-171b 11-253 Arctic curtain fastener
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-171a 11-253 tape hook:
Antenna mount (M997, M997A1, Installation . . . . . . . . . . . . . . . . . . . . 12-78b 12-112
M997A2), radio:
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-78a 12-112
Installation . . . . . . . . . . . . . . . . . . . . 11-172b 11-254
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-172a 11-254 Arctic defroster ducting:
Antenna mounting bracket, rear: Installation . . . . . . . . . . . . . . . . . . . . 12-50b 12-74
Installation . . . . . . . . . . . . . . . . . . . . 12-138b 12-212 Removal . . . . . . . . . . . . . . . . . . . . . . . . . 12-50a 12-73
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-138a 12-212 Arctic defroster nozzle, left:
Antenna mounting bracket, Installation . . . . . . . . . . . . . . . . . . . . 12-51b 12-76
troop/cargo winterization: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-51a 12-75
Installation . . . . . . . . . . . . . . . . . . . . 12-125b 12-197
Removal. . . . . . . . . . . . . . . . . . . . . . . . 12-125a 12-197
INDEX 2 Change 1
TM 9-2320-280-20-3
INDEX (Cont’d)
Para Page Para Page
A (Cont’d)
Arctic defroster nozzle, right: Arctic heater filter-to-
Installation . . . . . . . . . . . . . . . . . . . . 12-52b 12-78 bulkhead fuel supply line:
Arctic diverter box: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-34a 12-50
Assembly . . . . . . . . . . . . . . . . . . . . 12-49c 12-72 Arctic heater filter-to-
Disassembly. . . . . . . . . . . . . . . . . . . . 12-49b 12-72 heater fuel supply hose:
Installation. . . . . . . . . . . . . . . . . . . . . 12-49d 12-72 Installation . . . . . . . . . . . . . . . . . . . . 12-35b 12-52
Arctic diverter box cover: Arctic heater front cowl
Installation . . . . . . . . . . . . . . . . . . . . 12-55b 12-81 insulation:
Installation . . . . . . . . . . . . . . . . . . . . 12-46b 12-68
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-55a 12-81
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-46a 12-68
Arctic diverter ducting:
Arctic heater fuel filter assembly:
Arctic foam insulation strip: Arctic heater fuel pump:
Arctic heater assembly: Arctic heater fuel supply hose:
Arctic heater battery box plugs: Arctic heater fuel supply
Installation . . . . . . . . . . . . . . . . . . . . 12-45b 12-67 line bulkhead coupling:
Arctic heater bracket assembly: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-33a 12-48
Installation . . . . . . . . . . . . . . . . . . . . 12-44b 12-66 Arctic heater fuel supply
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-44a 12-66 tube assembly:
Arctic heater CDR valve Installation . . . . . . . . . . . . . . . . . . . . 12-28b 12-42
tube assembly: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-28a 12-42
Arctic heater hose:
Installation . . . . . . . . . . . . . . . . . . . . 12-36b 12-54
Installation . . . . . . . . . . . . . . . . . . . . 12-54b 12-80
Arctic heater control box Arctic heater nozzle:
assembly maintenance: Installation . . . . . . . . . . . . . . . . . . . . 12-53b 12-79
Assembly . . . . . . . . . . . . . . . . . . . . . . 12-43b 12-64 Removal . . . . . . . . . . . . . . . . . . . . . . . 12-53a 12-79
Disassembly . . . . . . . . . . . . . . . . . . . 12-43a 12-64 Arctic heater oil pan shroud:
Arctic heater control box Installation. . . . . . . . . . . . . . . . . . . . . 12-48.2b 12-70.4
assembly replacement: Removal . . . . . . . . . . . . . . . . . . . . . . . . 12-48.2a 12-70.4
Installation . . . . . . . . . . . . . . . . . . . . 12-42b 12-62 Arctic heater plenum assembly:
Arctic heater control cable: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-37a 12-55
Adjustment . . . . . . . . . . . . . . . . . . 12-42.1c 12-62.2 Arctic heater plenum cover:
Installation . . . . . . . . . . . . . . . . . . 12-42.1b 12-62.2 Installation . . . . . . . . . . . . . . . . . . . . 12-39b 12-57
Removal . . . . . . . . . . . . . . . . . . . . . 12-42.1a 12-62.2 Removal . . . . . . . . . . . . . . . . . . . . . . . 12-39a 12-57
Arctic heater diverter box cover: Arctic heater plenum hose:
Arctic heater ducting: Arctic heater pump-to-
bulkhead fuel supply line:
Installation. . . . . . . . . . . . . . . . . . . . . 12-48.1b 12-70.2
Installation . . . . . . . . . . . . . . . . . . . . 12-32b 12-46
Removal. . . . . . . . . . . . . . . . . . . . . . . . 12-48.1a 12-70.2 Removal . . . . . . . . . . . . . . . . . . . . . . . 12-32a 12-46
Arctic heater exhaust Arctic heater pump-to-
diverter cable assembly: hose fuel supply line:
Adjustment . . . . . . . . . . . . . . . . . . . . 12-48c 12-70 Installation . . . . . . . . . . . . . . . . . . . . 12-31b 12-45
Installation . . . . . . . . . . . . . . . . . . . . 12-48b 12-70 Removal . . . . . . . . . . . . . . . . . . . . . . . 12-31a 12-45
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-48a 12-70
Change 1 INDEX 3
TM 9-2320-280-20-3
INDEX (Cont’d)
Para Page Para Page
A (Cont’d)
Arctic heater regulator: AS 1729/VRC antenna:
Arctic heater tank-to- Attendant seat:
hose fuel supply line: Assembly . . . . . . . . . . . . . . . . . . . . . . 11-157c 11-232
Arctic top cover assembly: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-157a 11-232
Installation . . . . . . . . . . . . . . . . . . . . 12-72b 12-105 Attendant seat guide rail:
Arctic window: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-158a 11-234
Installation . . . . . . . . . . . . . . . . . . . . 12-75b 12-108 Attendant seat stowage brackets:
Arctic winterization crew top kits: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-177a 11-259
Maintenance task summary . . . . 12-71 12-104 Auxiliary shelf:
Arctic winterization kit: Installation . . . . . . . . . . . . . . . . . . . . 12-131b 12-203
Maintenance task summary . . . . 12-25 12-36 Removal . . . . . . . . . . . . . . . . . . . . . . . 12-131a 12-203
Armament cover and seal:
Installation . . . . . . . . . . . . . . . . . . . . 11-62b 11-83 B
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-62a 11-83
Armament mount panel: Backrest pad, weapon station:
Armored grille, hood front: Ballistic crew door:
Installation . . . . . . . . . . . . . . . . . . . . 11-35b 11-54 Adjustment . . . . . . . . . . . . . . . . . . . . 11-2d 11-6
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-35a 11-54 Inspection . . . . . . . . . . . . . . . . . . . . . 11-2c 11-6
Armored grille, hood top: Installation . . . . . . . . . . . . . . . . . . . . 11-2b 11-5
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-34a 11-53 Ballistic crew door hinge:
Armor plate, footwell: Installation . . . . . . . . . . . . . . . . . . . . 11-3b 11-8
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-38a 11-57 Ballistic crew door latch:
Armor plate, hood center: Installation . . . . . . . . . . . . . . . . . . . . 11-11b 11-18
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-11a 11-18
Installation . . . . . . . . . . . . . . . . . . . . 11-33b 11-52
Ballistic crew door latch tube:
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-33a 11-52
Installation . . . . . . . . . . . . . . . . . . . . 11-12b 11-19
Armor plate, hood side: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-12a 11-19
Installation . . . . . . . . . . . . . . . . . . . . 11-32b 11-51 Ballistic crew door seal:
Armor plate, left cowl: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-10a 11-17
Installation . . . . . . . . . . . . . . . . . . . . 11-37b 11-56 Ballistic crew door
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-37a 11-56 window assembly:
Armor plate, left wheelhouse: Assembly . . . . . . . . . . . . . . . . . . . . . . 11-7c 11-12
Armor plate, right cowl: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-7a 11-12
Installation . . . . . . . . . . . . . . . . . . . . 11-36b 11-55 Ballistic crew door window
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-36a 11-55 protective shield:
Armor plate, right wheelhouse: Initial installation . . . . . . . . . . . . . . 11-8a 11-14
Installation . . . . . . . . . . . . . . . . . . . . 11-39b 11-58 Installation. . . . . . . . . . . . . . . . . . . . . 11-8c 11-15
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-39a 11-58 Removal . . . . . . . . . . . . . . . . . . . . . . . 11-8b 11-15
Armor plate, tailgate: Ballistic crew door window stop:
INDEX 4 Change 1
TM 9-2320-280-20-3
INDEX (Cont’d)
Para Page Para Page
B (Cont’d)
Base plate strap: Blackout/dome light switch,
Installation . . . . . . . . . . . . . . . . . . . . 12-150b 12-240 troop/cargo winterization:
Battery box cover and companion seat: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-106a 12-156
Installation . . . . . . . . . . . . . . . . . . . . 10-35b 10-62 Blackout/dome light wiring
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-35a 10-62 harness, troop/cargo
Battery box cover catch: winterization:
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-40a 10-68
Battery box cover latch: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-105a 12-154
Installation . . . . . . . . . . . . . . . . . . . . 10-36b 10-63 Blade and arm, windshield wiper:
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-36a 10-63 Installation . . . . . . . . . . . . . . . . . . . . 10-70c 10-116
Battery box plugs, arctic heater: Removal . . . . . . . . . . . . . . . . . . . . . . . 10-70a 10-116
Installation . . . . . . . . . . . . . . . . . . . . 12-45b 12-67 Repair (optional) . . . . . . . . . . . . . . . 10-70b 10-116
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-45a 12-67 Blower assembly:
Battery bracket, front night sight: Installation . . . . . . . . . . . . . . . . . . . . 11-212b 11-322
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-84a 11-126 Blower motor and housing:
Battery bracket, rear night sight: Blower housing installation . . . . 11-198d 11-292
Installation . . . . . . . . . . . . . . . . . . . . 11-85b 11-127
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-85a 11-127 Blower housing removal . . . . . . . 11-198c 11-292
Battery rack assembly, Blower motor installation . . . . . . 11-198f 11-294
missile guidance set (MGS): Blower motor removal . . . . . . . . . 11-198e 11-294
Installation . . . . . . . . . . . . . . . . . . . . 11-77b 11-118 Closing blower housing . . . . . . . . 11-198b 11-292
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-77a 11-118 Opening blower housing . . . . . . . 11-198a 11-292
Battery strap (L119), gun display unit: Blower motor resistor:
Belt, compressor: Blower outlet deflector:
Adjustment . . . . . . . . . . . . . . . . . . . . 11-202c 11-306
Installation . . . . . . . . . . . . . . . . . . . . 11-210b 11-318
Installation . . . . . . . . . . . . . . . . . . . . 11-202b 11-306
Bipod stowage tray: Body:
Assembly . . . . . . . . . . . . . . . . . . . . . . 12-152c 12-242 Maintenance task summary. . . . 10-1 10-1
Disassembly . . . . . . . . . . . . . . . . . . . 12-152b 12-242 Body accessories:
Installation . . . . . . . . . . . . . . . . . . . . 12-152d 12-242 Maintenance task summary. . . . 10-69 10-115
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-152a 12-242 Body hinge mount:
Blackout curtain, troop/cargo Installation . . . . . . . . . . . . . . . . . . . . 10-64b 10-103
winterization: Removal . . . . . . . . . . . . . . . . . . . . . . . 10-64a 10-103
Installation . . . . . . . . . . . . . . . . . . . . 12-104b 12-153 Body repair:
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-104a 12-153 General. . . . . . . . . . . . . . . . . . . . . . . . 10-66a 10-105
Blackout/dome light assembly, Inspection . . . . . . . . . . . . . . . . . . . . . 10-66b 10-106
troop/cargo winterization: Rivet replacement . . . . . . . . . . . . . 10-66c 10-106
Installation . . . . . . . . . . . . . . . . . . . . 12-108b 12-160 Boot, heater:
Blackout/dome light door switch, Removal . . . . . . . . . . . . . . . . . . . . . . . 10-96a 10-165
troop/cargo winterization: Boresight collimator or night
Installation . . . . . . . . . . . . . . . . . . . . 12-107b 12-158
sight mounting spacers:
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-107a 12-158
Blackout/dome light lamp, Installation . . . . . . . . . . . . . . . . . . . . 11-86b 11-128
Installation . . . . . . . . . . . . . . . . . . . . 12-109b 12-161 Bow and troop/cargo winterization
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-109a 12-161 troop seat assembly:
Installation . . . . . . . . . . . . . . . . . . . . 12-121b 12-192
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-121a 12-190
Change 1 INDEX 5
TM 9-2320-280-20-3
INDEX (Cont’d)
Para Page Para Page
B (Cont’d)
Bow pivot bracket, rear: Bracket (L119), rear bumper brace:
“B” pillar: Bracket (L119), rear bumper
Installation. . . . . . . . . . . . . . . . . . . . . 10-67b 10-111 inner mounting:
Removal. . . . . . . . . . . . . . . . . . . . . . . . 10-67a 10-111 Installation . . . . . . . . . . . . . . . . . . . . 12-169b 12-262
“B” pillar padding: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-169a 12-262
Installation. . . . . . . . . . . . . . . . . . . . . 11-30.1b 11-49 Bracket (L119), rear bumper
Removal. . . . . . . . . . . . . . . . . . . . . . . . 11-30.1a 11-49 outer mounting:
Brace (L119), rear bumper inner: Installation . . . . . . . . . . . . . . . . . . . . 12-167b 12-260
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-168a 12-261 Bracket (L119), rear tiedown:
Brace (L119), rear bumper outer: Installation . . . . . . . . . . . . . . . . . . . . 12-172b 12-265
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-166a 12-259 Bracket, lower rifle mount:
Bracket assembly, arctic heater: Installation . . . . . . . . . . . . . . . . . . . . 11-94b 11-136
Bracket (M16 A1 rifle/M203
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-44a 12-66
grenade launcher), rifle
Bracket assembly, gasoline
mounting clamp:
cook stove:
Installation . . . . . . . . . . . . . . . . . . . . 11-93b 11-135
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-89a 11-131 Bracket, mirror mounting:
Bracket assembly, heater Installation . . . . . . . . . . . . . . . . . . . . 10-81b 10-132
mounting (M996, M996A1): Removal . . . . . . . . . . . . . . . . . . . . . . . 10-81a 10-132
Installation . . . . . . . . . . . . . . . . . . . . 11-208b 11-314 Bracket, mortar barrel stowage:
Bracket, cargo shell door Removal . . . . . . . . . . . . . . . . . . . . . . . 12-159a 12-250
gas spring mounting:
Bracket, mounting, dual TSEC/KY57
Installation . . . . . . . . . . . . . . . . . . . . 11-29b 11-47
and control switch bracket:
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-29a 11-47
Installation . . . . . . . . . . . . . . . . . . . . 12-134b 12-207
Bracket, exhaust reinforcement:
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-134a 12-207
Installation . . . . . . . . . . . . . . . . . . . . 12-15b 12-18
Bracket, pioneer tool stowage
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-15a 12-18
tray mounting:
Bracket, field glasses:
Bracket, fire extinguisher: Bracket, rear antenna mounting:
Bracket, front radio rack mounting: Bracket, rear bow pivot:
Bracket, handset: Bracket, rifle mounting clamp:
Bracket, headphone mounting: Bracket, shelter carrier tailgate:
Bracket, hood prop rod: Bracket, shelter mounting:
Assembly . . . . . . . . . . . . . . . . . . . . . . 10-4d 10-6 Installation . . . . . . . . . . . . . . . . . . . . 11-116b 11-163
Disassembly . . . . . . . . . . . . . . . . . . . 10-4b 10-6 Removal . . . . . . . . . . . . . . . . . . . . . . . 11-116a 11-163
Inspection . . . . . . . . . . . . . . . . . . . . . 10-4c 10-6 Brackets, cargo bulkhead
Installation . . . . . . . . . . . . . . . . . . . . 10-4e 10-7 mounting:
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-54a 10-89
INDEX 6 Change 1
TM 9-2320-280-20-3
INDEX (Cont’d)
Para Page Para Page
B (Cont’d)
Brackets, M11 decontamination: Bulkhead door latch:
Installation . . . . . . . . . . . . . . . . . . . . 10-68 10-112 Installation . . . . . . . . . . . . . . . . . . . . 11-156b 11-230
Brackets, NBC heater: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-156a 11-228
Installation . . . . . . . . . . . . . . . . . . . . 11-165b 11-243 Bumper brace bracket (L119),
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-165a 11-243 rear:
Bracket, spineboard mounting: Installation . . . . . . . . . . . . . . . . . . . . 12-165b 12-258
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-148a 11-216 Bumper inner brace (L119), rear:
Brackets, tailgate chain: Installation . . . . . . . . . . . . . . . . . . . . 12-168b 12-261
Installation . . . . . . . . . . . . . . . . . . . . 10-60b 10-96
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-168a 12-261
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-60a 10-96
Bracket, stowage mount: Bumper inner mounting
Installation . . . . . . . . . . . . . . . . . . . . 11-70b 11-100 bracket (L119), rear:
Bracket, tripod: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-169a 12-262
Installation . . . . . . . . . . . . . . . . . . . . 11-102b 11-144 Bumper (L119), rear:
Bracket, tripod head mounting: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-164a 12-257
Installation . . . . . . . . . . . . . . . . . . . . 11-79b 11-121 Bumper lifting shackle (L119),
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-79a 11-121 rear:
Bracket, tripod leg mounting: Installation . . . . . . . . . . . . . . . . . . . . 12-171b 12-264
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-78a 11-120 Bumper, litter handle:
Bracket, upper litter rack latch: Installation . . . . . . . . . . . . . . . . . . . . 11-147b 11-215
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-143a 11-211 Bumper outer brace (L119), rear:
Bracket, upper litter rack Installation . . . . . . . . . . . . . . . . . . . . 12-166b 12-259
striker support: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-166a 12-259
Installation . . . . . . . . . . . . . . . . . . . . 11-141b 11-208 Bumper outer mounting
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-141a 11-208 bracket (L119), rear:
Bracket, upper litter rack Installation . . . . . . . . . . . . . . . . . . . . 12-167b 12-260
support: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-167a 12-260
Installation . . . . . . . . . . . . . . . . . . . . 11-144b 11-212 Bumper pad, weapon station:
Bracket, vehicle power Removal . . . . . . . . . . . . . . . . . . . . . . . 11-48a 11-69
conditioner (VPC) mounting: Bumper, water can:
Bracket, windshield mounting: Bumper, water can/M13 decon
Installation . . . . . . . . . . . . . . . . . . . . 12-5b 12-7
can:
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-5a 12-7
Installation . . . . . . . . . . . . . . . . . . . . 11-109b 11-151
Brushguard assembly replacement:
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-109a 11-151
Brushguard assembly
replacement. . . . . . . . . . . . . . . . . . . 12-187a 12-310
C
Lanyard replacement . . . . . . . . . . . 12-187e 12-311
Pivot brace replacement. . . . . . . . . 12-187c 12-310
Quick release brace Cab enclosure panel:
replacement . . . . . . . . . . . . . . . . . . . 12-187d 12-310 Installation . . . . . . . . . . . . . . . . . . . . 11-122b 11-172
Tube assembly replacement . . . . . 12-187b 12-310 Removal . . . . . . . . . . . . . . . . . . . . . . . 11-122a 11-172
Bulkhead, cargo: Cable, alternator, 100 ampere
Installation . . . . . . . . . . . . . . . . . . . . 10-53b 10-88 (12446821-2):
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-53a 10-88 Installation . . . . . . . . . . . . . . . . . . . . . 12-22.1b 12-28.2
Bulkhead door: Removal. . . . . . . . . . . . . . . . . . . . . . . . 12-22.1a 12-28.2
Installation . . . . . . . . . . . . . . . . . . . . 11-155b 11-226
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-155a 11-224
Change 1 INDEX 7
TM 9-2320-280-20-3
INDEX (Cont’d)
Para Page Para Page
C (Cont’d)
Cable, arctic heater control: Cargo barrier channel:
Adjustment. . . . . . . . . . . . . . . . . . . . . 12-42.1c 12-63.1 Installation . . . . . . . . . . . . . . . . . . . . 12-190b 12-314
Installation . . . . . . . . . . . . . . . . . . . . . 12-42.1b 12-63.1 Removal . . . . . . . . . . . . . . . . . . . . . . . 12-190a 12-314
Removal. . . . . . . . . . . . . . . . . . . . . . . . 12-42.1a 12-63.1 Cargo barrier extension:
Cable, arctic heater exhaust Assembly . . . . . . . . . . . . . . . . . . . . . . 10-55c 10-90
diverter: Disassembly . . . . . . . . . . . . . . . . . . . 10-55b 10-90
Adjustment . . . . . . . . . . . . . . . . . . . . 12-48c 12-70 Installation . . . . . . . . . . . . . . . . . . . . 10-55d 10-90
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-48a 12-70 Cargo bulkhead:
Cable, cargo shell door Installation . . . . . . . . . . . . . . . . . . . . 10-53b 10-88
retention: Removal . . . . . . . . . . . . . . . . . . . . . . . 10-53a 10-88
Installation . . . . . . . . . . . . . . . . . . . . 11-20b 11-34 Cargo bulkhead:
Cable, heater control and Removal . . . . . . . . . . . . . . . . . . . . . . . 11-111a 11-153
shutoff valve: Cargo bulkhead mounting
Adjustment . . . . . . . . . . . . . . . . . . . . 10-90 10-150 brackets:
Cable, power, front radio: Installation . . . . . . . . . . . . . . . . . . . . 10-54b 10-89
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-141a 12-221 Cargo floor access cover (M1123):
Cable, rear radio rack power: Inspection. . . . . . . . . . . . . . . . . . . . . . 10-31.1b 10-56.2
Installation . . . . . . . . . . . . . . . . . . . . 12-147b 12-234 Installation . . . . . . . . . . . . . . . . . . . . 10-31.1c 10-56.2
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-147a 12-232 Removal . . . . . . . . . . . . . . . . . . . . . . . 10-31.1a 10-56.2
Cable, rear steps retaining: Cargo shell door:
Installation . . . . . . . . . . . . . . . . . . . . 11-136b 11-198 Adjustment . . . . . . . . . . . . . . . . . . . . 11-13c 11-24
Cables, duct door control: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-13a 11-20
Cable adjustment . . . . . . . . . . . . . . 11-199g 11-300 Cargo shell door dovetail assembly:
Evaporator intake cable Adjustment . . . . . . . . . . . . . . . . . . . . 11-19c 11-32
installation . . . . . . . . . . . . . . . . . . . 11-199b 11-296 Installation . . . . . . . . . . . . . . . . . . . . 11-19b 11-32
Evaporator intake cable Removal . . . . . . . . . . . . . . . . . . . . . . . 11-19a 11-32
removal . . . . . . . . . . . . . . . . . . . . . . 11-199a 11-296 Cargo shell door dovetail spring:
Heater/air-conditioning Installation . . . . . . . . . . . . . . . . . . . . 11-28b 11-46
outlet cable installation . . . . . . . 11-199d 11-298 Removal . . . . . . . . . . . . . . . . . . . . . . . 11-28a 11-46
Heater/air-conditioning Cargo shell door front striker:
outlet cable removal . . . . . . . . . . 11-199c 11-298 Installation . . . . . . . . . . . . . . . . . . . . 11-25b 11-43
Heater intake cable Removal . . . . . . . . . . . . . . . . . . . . . . . 11-25a 11-43
installation . . . . . . . . . . . . . . . . . . . 11-199f 11-298 Cargo shell door gas spring:
Heater intake cable Assembly . . . . . . . . . . . . . . . . . . . . . . 11-21d 11-38
removal . . . . . . . . . . . . . . . . . . . . . . 11-199e 11-298 Disassembly . . . . . . . . . . . . . . . . . . . 11-21c 11-38
Cables, rear antenna: Installation . . . . . . . . . . . . . . . . . . . . 11-21e 11-38
Installation . . . . . . . . . . . . . . . . . . . . 12-140b 12-217
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-21b 11-37
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-140a 12-214
Rotating . . . . . . . . . . . . . . . . . . . . . . . 11-21a 11-35
Cable stowage cleat:
Installation . . . . . . . . . . . . . . . . . . . . 11-68b 11-98 Cargo shell door gas spring
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-68a 11-98 mounting bracket:
Cable, winch: Installation . . . . . . . . . . . . . . . . . . . . 11-29b 11-47
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-110a 10-190 Cargo shell door grab handle:
Camouflage rack: Installation . . . . . . . . . . . . . . . . . . . . 11-15b 11-27
Assembly . . . . . . . . . . . . . . . . . . . . . . 12-183c 12-280 Removal . . . . . . . . . . . . . . . . . . . . . . . 11-15a 11-27
Disassembly . . . . . . . . . . . . . . . . . . . 12-183b 12-279 Cargo shell door handle latch:
INDEX 8 Change 1
TM 9-2320-280-20-3
INDEX (Cont’d)
Para Page Para Page
C (Cont’d)
Cargo shell door latch: Chain, shelter carrier tailgate:
Adjusting . . . . . . . . . . . . . . . . . . . . . . 11-17c 11-29 Assembly . . . . . . . . . . . . . . . . . . . . . . 11-119c 11-166
Cargo shell door latch rod: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-119a 11-166
Adjustment . . . . . . . . . . . . . . . . . . . . 11-18c 11-30 Channel assembly, arctic curtain
(2-man crew):
Installation . . . . . . . . . . . . . . . . . . . . 11-18b 11-30
Installation . . . . . . . . . . . . . . . . . . . . 12-76b 12-109
Cargo shell door liner: Circuit breaker, troop/cargo
Installation . . . . . . . . . . . . . . . . . . . . 11-30b 11-48 winterization:
Cargo shell door rear striker: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-103a 12-152
Installation . . . . . . . . . . . . . . . . . . . . 11-26b 11-44 Clamp, rifle mounting:
Cargo shell door rear striker Removal . . . . . . . . . . . . . . . . . . . . . . . 11-91a 11-133
mounting plate: Cleaning staff stowage clip:
Cargo shell door retention cable: Cleat, cable stowage:
Installation . . . . . . . . . . . . . . . . . . . . 11-68b 11-98
Installation . . . . . . . . . . . . . . . . . . . . 11-20b 11-34
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-68a 11-98
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-20a 11-34 Clip, cleaning staff stowage:
Cargo shell door seal: Installation . . . . . . . . . . . . . . . . . . . . 12-151b 12-241
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-24a 11-42 Clip, Red Cross placard
Cargo shell door seal protector: retaining:
Cargo shell door strap: Communications kits:
Installation . . . . . . . . . . . . . . . . . . . . 11-22b 11-40 Maintenance task summary. . . . 12-129 12-201
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-22a 11-40 Compressor belt:
Cargo shell door wire handle Adjustment . . . . . . . . . . . . . . . . . . . . 11-202c 11-306
lock: Installation . . . . . . . . . . . . . . . . . . . . 11-202b 11-306
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-202a 11-306
Installation . . . . . . . . . . . . . . . . . . . . 11-14b 11-26 Condenser cooling fan:
Cargo shell roof insulation Removal . . . . . . . . . . . . . . . . . . . . . . . 11-201a 11-304
panel: Control box assembly
Installation . . . . . . . . . . . . . . . . . . . . 11-31b 11-50 arctic heater maintenance:
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-31a 11-50 Assembly . . . . . . . . . . . . . . . . . . . . . . 12-43b 12-64
Cargo tiedown: Disassembly . . . . . . . . . . . . . . . . . . . 12-43a 12-64
Installation . . . . . . . . . . . . . . . . . . . . 10-56b 10-92 Control box assembly,
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-56a 10-92 arctic heater:
Catch, battery box cover Installation . . . . . . . . . . . . . . . . . . . . 12-42b 12-62
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-40a 10-68 Control box, winch:
CDR valve tube assembly, Installation . . . . . . . . . . . . . . . . . . . . 10-109b 10-188
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-109a 10-188
arctic heater: Coolant base, night sight:
CDR valve vent line: Cover and latch, medical stowage:
Change 1 INDEX 9
TM 9-2320-280-20-3
INDEX (Cont’d)
Para Page Para Page
C (Cont’d)
Cover and seal, armament: Curtain assembly, arctic:
Cover assembly, arctic top: Cushions, companion seat
Installation . . . . . . . . . . . . . . . . . . . . 12-72b 12-105 and seat back:
Cover assembly, troop/cargo Removal . . . . . . . . . . . . . . . . . . . . . . . 10-37a 10-64
winterization top: Cushions, driver’s seat
Installation . . . . . . . . . . . . . . . . . . . . 12-119b 12-182 and seat back:
Cover, cargo floor access: Removal . . . . . . . . . . . . . . . . . . . . . . . 10-33a 10-60
Inspection. . . . . . . . . . . . . . . . . . . . 10-31.1b 10-56.2 Cushions, passenger seat
Installation . . . . . . . . . . . . . . . . . . 10-31.1c 10-56.2 and seat back:
Removal . . . . . . . . . . . . . . . . . . . 10-31.1a 10-56.2 Installation . . . . . . . . . . . . . . . . . . . . 10-46b 10-74
Cover, engine access: Removal . . . . . . . . . . . . . . . . . . . . . . . 10-46a 10-74
Assembly . . . . . . . . . . . . . . . . . . . . . . 10-15c 10-24
Disassembly . . . . . . . . . . . . . . . . . . . 10-15b 10-22 D
Installation . . . . . . . . . . . . . . . . . . . . 10-15d 10-26
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-15a 10-22 Data plate, troop/cargo
Cover, passenger seat and winterization:
storage compartment: Installation . . . . . . . . . . . . . . . . . . . . 12-128b 12-200
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-43a 10-71 Day sight stowage bracket:
Cowl armor plate, left: Installation . . . . . . . . . . . . . . . . . . . . 11-81b 11-123
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-37a 11-56 Deep water fording kit:
Maintenance task summary. . . . 12-1 12-1
Cowl armor plate, right:
Deep water fording kit air
Installation . . . . . . . . . . . . . . . . . . . . 11-36b 11-55
intake assembly:
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-36a 11-55
Installation . . . . . . . . . . . . . . . . . . . . 12-3b 12-4
Cowl insulation, arctic Removal . . . . . . . . . . . . . . . . . . . . . . . 12-3a 12-4
heater front: Deep water fording kit
Installation . . . . . . . . . . . . . . . . . . . . 12-46b 12-68 exhaust assembly:
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-46a 12-68 Inspection . . . . . . . . . . . . . . . . . . . . . 12-2b 12-2
Cowl insulation, left front: Installation . . . . . . . . . . . . . . . . . . . . 12-2c 12-3
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-26a 10-46 Deep water fording sensor cup:
Cowl insulation, left outer: Installation . . . . . . . . . . . . . . . . . . . . 12-12b 12-15
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-25a 10-45 Deflector, blower outlet:
Cowl insulation panel, left inner: Installation . . . . . . . . . . . . . . . . . . . . 11-210b 11-318
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-31a 10-52 Defrost control:
Cowl insulation panel, right inner: Installation . . . . . . . . . . . . . . . . . . . . 10-88b 10-146
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-30a 10-51 Defroster ducting
Cowl insulation, right front: (All except M1097, M1123):
“C” pillar: Defroster ducting
Installation . . . . . . . . . . . . . . . . . . . . 10-99b 10-168 (M1097, M1123):
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-99a 10-168 Installation . . . . . . . . . . . . . . . . . . . . 10-96.1b 10-164.2
“C” pillar reinforcement brackets: Removal . . . . . . . . . . . . . . . . . . . . . . . 10-96.1a 10-164.2
Installation . . . . . . . . . . . . . . . . . . . . 10-105 10-177 Defroster nozzle, left:
Curtain angle assembly, arctic: Installation . . . . . . . . . . . . . . . . . . . . 10-94b 10-160
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-74a 12-107
INDEX 10 Change 1
TM 9-2320-280-20-3
INDEX (Cont’d)
Para Page Para Page
D (Cont’d)
Defroster nozzle, right: Door, exterior stowage:
Diverter, air (M996, M996A1): Door, fixed rear:
Diverter assembly, troop/cargo Door handle assembly:
winterization heater: Installation . . . . . . . . . . . . . . . . . . . . 10-13c 10-20
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-96a 12-140 Repair . . . . . . . . . . . . . . . . . . . . . . . . . 10-13b 10-18
Diverter box (All except M998A2): Door handles, rear:
Diverter box, arctic: Door hinge, ballistic crew:
Assembly . . . . . . . . . . . . . . . . . . . . . . 12-49c 12-72 Installation . . . . . . . . . . . . . . . . . . . . 11-3b 11-8
Installation . . . . . . . . . . . . . . . . . . . . 12-49d 12-72 Door hinge, rear:
Diverter box (M998A2): Removal . . . . . . . . . . . . . . . . . . . . . . . 11-126a 11-185
Installation . . . . . . . . . . . . . . . . . . . . 10-97.1b 10-166 Door hinge, soft top:
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-97.1a 10-166 Installation . . . . . . . . . . . . . . . . . . . . 10-101b 10-170
Diverter box cover: Removal . . . . . . . . . . . . . . . . . . . . . . . 10-101a 10-170
Installation . . . . . . . . . . . . . . . . . . . . 10-96.3b 10-164.5 Door holder assembly, rear:
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-96.3a 10-164.5 Installation . . . . . . . . . . . . . . . . . . . . 11-132b 11-192
Diverter ducting: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-132a 11-192
Installation . . . . . . . . . . . . . . . . . . . . 10-96.4b 10-164.6 Door latch assembly
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-96.4a 10-164.6 and guide, rear:
Diverter box cover, arctic heater: Installation . . . . . . . . . . . . . . . . . . . . 11-128b 11-187
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-47a 12-69 Door latch, bulkhead:
Diverter manifold and housing: Installation . . . . . . . . . . . . . . . . . . . . 11-156b 11-230
Installation . . . . . . . . . . . . . . . . . . . . 10-92.1b 10-154.2 Removal . . . . . . . . . . . . . . . . . . . . . . . 11-156a 11-228
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-92.1a 10-154.2 Door latch, NBC compartment:
Installation . . . . . . . . . . . . . . . . . . . . 11-163b 11-241
Door, air intake duct:
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-163a 11-241
Installation . . . . . . . . . . . . . . . . . . . . 11-185b 11-269
Door latch rod striker guides
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-185a 11-269
and brackets, rear:
Door and frame assembly,
Bracket installation. . . . . . . . . . . . 11-131d 11-190
troop/cargo winterization:
Bracket removal . . . . . . . . . . . . . . . 11-131c 11-190
Installation . . . . . . . . . . . . . . . . . . . . 12-117b 12-174
Striker guide adjustment . . . . . . 11-131e 11-190
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-117a 12-172 Striker guide installation . . . . . . 11-131b 11-190
Door, ballistic crew: Striker guide removal . . . . . . . . . . 11-131a 11-190
Adjustment . . . . . . . . . . . . . . . . . . . . 11-2d 11-6 Door liner, cargo shell:
Inspection . . . . . . . . . . . . . . . . . . . . . 11-2c 11-6 Installation . . . . . . . . . . . . . . . . . . . . 11-30b 11-48
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-2a 11-5 Door, litter stowage:
Door, bulkhead: Installation . . . . . . . . . . . . . . . . . . . . 11-159b 11-235
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-155a 11-224 Door (M996, M996A1), NBC:
Door, cargo shell: Installation . . . . . . . . . . . . . . . . . . . . 11-183b 11-266
Adjustment . . . . . . . . . . . . . . . . . . . . 11-13c 11-24 Removal . . . . . . . . . . . . . . . . . . . . . . . 11-183a 11-266
Installation . . . . . . . . . . . . . . . . . . . . 11-13b 11-22 Door (M997, M997A1, M997A2),
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-13a 11-20 NBC compartment:
Door cover, troop/cargo Installation . . . . . . . . . . . . . . . . . . . . 11-162b 11-240
winterization fixed: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-162a 11-240
Installation . . . . . . . . . . . . . . . . . . . . 12-113b 12-166
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-113a 12-166
Change 1 INDEX 11
TM 9-2320-280-20-3
INDEX (Cont’d)
Para Page Para Page
D (Cont’d)
Door, rear: Duct door, air intake:
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-125a 11-183 Duct door control cables:
Door seal protector, rear: Cable adjustment . . . . . . . . . . . . . . 11-199g 11-300
Installation . . . . . . . . . . . . . . . . . . . . 11-129b 11-188 Evaporator intake cable
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-129a 11-188 installation . . . . . . . . . . . . . . . . . . . 11-199b 11-296
Door seals, rear: Evaporator intake cable
Installation . . . . . . . . . . . . . . . . . . . . 11-130b 11-189 removal . . . . . . . . . . . . . . . . . . . . . . 11-199a 11-296
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-130a 11-189 Heater/air-conditioning
Door, soft top: outlet cable installation . . . . . . . 11-199d 11-298
Adjustment . . . . . . . . . . . . . . . . . . . . 10-102 10-172 Heater/air-conditioning
Door, stowage: outlet cable removal . . . . . . . . . . 11-199c 11-298
Installation . . . . . . . . . . . . . . . . . . . . 11-152b 11-221 Heater intake cable
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-152a 11-221 installation . . . . . . . . . . . . . . . . . . . 11-199f 11-298
Door striker, soft top: Heater intake cable removal . . . 11-199e 11-298
Installation . . . . . . . . . . . . . . . . . . . . 10-103b 10-174 Duct, heat/air-conditioning:
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-103a 10-174 Assembly . . . . . . . . . . . . . . . . . . . . . . 11-211c 11-320
Door, troop/cargo winterization: Disassembly . . . . . . . . . . . . . . . . . . . 11-211b 11-320
Adjustment . . . . . . . . . . . . . . . . . . . . 12-116 12-170 Installation . . . . . . . . . . . . . . . . . . . . 11-211d 11-319
Door vent assembly, rear: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-211a 11-319
Installation . . . . . . . . . . . . . . . . . . . . 11-178b 11-260 Ducting, defroster:
Dovetail assembly, cargo shell door: Removal . . . . . . . . . . . . . . . . . . . . . . . 10-93a 10-156
Adjustment . . . . . . . . . . . . . . . . . . . . 11-19c 11-32 Ducting, heater:
Dovetail spring, cargo shell door: Dust cap, air cleaner:
Drain tube, evaporator:
Installation . . . . . . . . . . . . . . . . . . . . 11-200b 11-302 E
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-200a 11-302
Drip rail, rear: Edge protector:
Driver’s seat assembly: Elbow, air cleaner extension:
Assembly . . . . . . . . . . . . . . . . . . . . . . 10-39b 10-66 Inspection . . . . . . . . . . . . . . . . . . . . . 12-4b 12-6
Disassembly . . . . . . . . . . . . . . . . . . . 10-39a 10-66 Installation . . . . . . . . . . . . . . . . . . . . 12-4c 12-6
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-38a 10-65 Elevation and depression
Driver’s seat and seat stop assembly:
back cushions: Assembly . . . . . . . . . . . . . . . . . . . . . . 11-73b 11-104
Installation . . . . . . . . . . . . . . . . . . . . 10-33b 10-60 Disassembly . . . . . . . . . . . . . . . . . . . 11-73a 11-104
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-33a 10-60 Enclosure assembly, troop/cargo
Driver’s seat frame: winterization top:
Driver’s seat retainer plate End closure, troop/cargo
assembly: winterization:
Installation . . . . . . . . . . . . . . . . . . . . 10-59b 10-95 Installation. . . . . . . . . . . . . . . . . . . . 12-118b 12-178
Duct, air
Installation . . . . . . . . . . . . . . . . . . . . 10-97b 10-165
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-97a 10-165
INDEX 12 Change 1
TM 9-2320-280-20-3
INDEX (Cont’d)
Para Page Para Page
E (Cont’d)
Engine access cover: Filter and bracket, NBC gas:
Installation . . . . . . . . . . . . . . . . . . . . 10-15d 10-26 Filter assembly, and bracket,
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-15a 10-22 NBC precleaner, particulate:
Engine access cover flexible Installation . . . . . . . . . . . . . . . . . . . . 11-168b 11-249
latch and holddown strike: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-168a 11-248
Installation . . . . . . . . . . . . . . . . . . . . 10-16b 10-27 Filter, heater fuel:
Engine left splash shield: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-192a 11-278
Assembly . . . . . . . . . . . . . . . . . . . . . . 10-17c 10-30 Fire extinguisher bracket:
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-17a 10-28 Fire extinguisher support:
Engine left splash shield access covers: Installation . . . . . . . . . . . . . . . . . . . . 10-58b 10-94
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-18a 10-32 Fixed rear door:
Engine right splash shield: Installation . . . . . . . . . . . . . . . . . . . . 10-14b 10-21
Disassembly . . . . . . . . . . . . . . . . . . . 10-20b 10-34 Floorboard, front:
Equipment rack: Floor bracket, troop/cargo
Installation . . . . . . . . . . . . . . . . . . . . 12-156b 12-247
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-156a 12-247 winterization:
Evaporator drain tube: Installation. . . . . . . . . . . . . . . . . . . . 12-99b 12-143
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-200a 11-302 Floor cover, troop/cargo
Exhaust assembly, deep winterization front and
water fording kit: rear cargo:
Inspection . . . . . . . . . . . . . . . . . . . . . 12-2b 12-2 Installation . . . . . . . . . . . . . . . . . . . . 12-110b 12-162
Installation . . . . . . . . . . . . . . . . . . . . 12-2c 12-3 Removal . . . . . . . . . . . . . . . . . . . . . . . 12-110a 12-162
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-2a 12-2 Floor cover, troop/cargo
Exhaust pipe, heater: winterization side:
Exhaust pipe (M997, M997A1, Floor drain hole plate:
M997A2), heater: Installation . . . . . . . . . . . . . . . . . . . . 12-188 12-312
Installation . . . . . . . . . . . . . . . . . . . . 11-189b 11-273 Floor heat duct louver:
Exhaust reinforcement bracket: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-196a 11-290
Installation . . . . . . . . . . . . . . . . . . . . 12-15b 12-18 Floor insulation, rear seat:
Expendable/durable supplies and Removal . . . . . . . . . . . . . . . . . . . . . . . 10-29a 10-50
materials list: Footman loop and strap:
Appendix C . . . . . . . . . . . . . . . . . . . . C-1 Installation . . . . . . . . . . . . . . . . . . . . 10-9b 10-14
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-9a 10-14
F Footwell armor plate:
Installation . . . . . . . . . . . . . . . . . . . . 11-38b 11-57
Fan, condenser cooling: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-38a 11-57
Installation . . . . . . . . . . . . . . . . . . . . 11-201b 11-304 Fording kit air intake
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-201a 11-304 assembly, deep water:
Field glasses bracket: Installation . . . . . . . . . . . . . . . . . . . . 12-3b 12-4
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-69a 11-99 Former, “A” pillar assembly:
Filter, air intake: Installation . . . . . . . . . . . . . . . . . . . . 10-98b 10-167
Cleaning. . . . . . . . . . . . . . . . . . . . . . . 11-205b 11-310 Removal . . . . . . . . . . . . . . . . . . . . . . . 10-98a 10-167
Inspection . . . . . . . . . . . . . . . . . . . . . 11-205a 11-310
Change 1 INDEX 13
TM 9-2320-280-20-3
INDEX (Cont’d)
Para Page Para Page
F (Cont’d)
Frame, driver’s seat: Fuel supply hose, troop/cargo
Installation . . . . . . . . . . . . . . . . . . . . 10-32b 10-58 winterization heater
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-32a 10-58 filter-to-bulkhead coupling:
Fuel can mounting bracket, Installation . . . . . . . . . . . . . . . . . . . . 12-91b 12-132
Installation . . . . . . . . . . . . . . . . . . . . 12-124b 12-196 Fuel supply hose, troop/cargo
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-124a 12-196 winterization heater:
Fuel can tray and hose: Installation . . . . . . . . . . . . . . . . . . . . 12-85b 12-123
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-80a 11-122 Fuel supply hose, troop/cargo
Fuel filler housing: winterization heater bulkhead:
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-2a 10-3
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-88a 12-127
Fuel filter assembly, arctic heater:
Installation . . . . . . . . . . . . . . . . . . . . 12-27b 12-40 Fuel supply hose, troop/cargo
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-27a 12-40 winterization heater filter-
Fuel filter assembly, troop/cargo to-heater:
winterization heater: Installation . . . . . . . . . . . . . . . . . . . . 12-92b 12-134
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-82a 12-119 Fuel supply line, arctic heater
Fuel filter, heater: filter-to-bulkhead:
Fuel lines replacement, heater: Fuel supply line, arctic heater
“B” beam fuel line. . . . . . . . . . . . . . 11-193d 11-282 pump-to-hose:
Bulkhead coupling . . . . . . . . . . . . . 11-193f 11-282 Installation . . . . . . . . . . . . . . . . . . . . 12-31b 12-45
Bulkhead fuel line . . . . . . . . . . . . . 11-193g 11-284 Removal . . . . . . . . . . . . . . . . . . . . . . . 12-31a 12-45
Cab fuel line . . . . . . . . . . . . . . . . . . . 11-193b 11-280 Fuel supply line, arctic heater
Filter fuel line . . . . . . . . . . . . . . . . . 11-193e 11-282 tank-to-hose:
Heater fuel line . . . . . . . . . . . . . . . . 11-193a 11-280 Installation . . . . . . . . . . . . . . . . . . . . 12-29b 12-43
Pump fuel line . . . . . . . . . . . . . . . . . 11-193h 11-284 Removal . . . . . . . . . . . . . . . . . . . . . . . 12-29a 12-43
Shutoff valve . . . . . . . . . . . . . . . . . . 11-193c 11-282
Fuel supply line, bulkhead
Tank fuel line and supply tube . 11-193i 11-284
Fuel pump, arctic heater: coupling, arctic heater:
Fuel pump, heater: Fuel supply line bulkhead
Installation . . . . . . . . . . . . . . . . . . . . 11-194b 11-286 coupling, troop/cargo
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-194a 11-286 winterization heater:
Fuel pump, troop/cargo Installation . . . . . . . . . . . . . . . . . . . . 12-90b 12-130
winterization heater: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-90a 12-129
Installation . . . . . . . . . . . . . . . . . . . . 12-81b 12-118 Fuel supply line, troop/cargo
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-81a 12-116 winterization heater bulkhead
Fuel supply hose, arctic heater: hose-to-bulkhead coupling:
Fuel supply hose, arctic heater Fuel supply line, troop/cargo
filter-to-heater: winterization heater pump-
Installation . . . . . . . . . . . . . . . . . . . . 12-35b 12-52 to-bulkhead:
Fuel supply hose, arctic heater Removal . . . . . . . . . . . . . . . . . . . . . . . 12-87a 12-125
pump-to-bulkhead: Fuel supply line, troop/cargo
Installation . . . . . . . . . . . . . . . . . . . . 12-32b 12-46 winterization heater pump-
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-32a 12-46 to-hose:
Installation . . . . . . . . . . . . . . . . . . . . 12-86b 12-124
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-86a 12-124
INDEX 14 Change 1
TM 9-2320-280-20-3
INDEX (Cont’d)
Para Page Para Page
F (Cont’d)
Fuel supply line, troop/cargo Grille, air inlet/outlet:
winterization heater tank- Installation . . . . . . . . . . . . . . . . . . . . 11-186b 11-270
to-hose: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-186a 11-270
Installation . . . . . . . . . . . . . . . . . . . . 12-84b 12-122 Grille and screen, hood:
Fuel supply tube assembly, Removal . . . . . . . . . . . . . . . . . . . . . . . 10-12a 10-17
Grille, hood top armored:
arctic heater: Installation . . . . . . . . . . . . . . . . . . . . 11-34b 11-53
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-28a 12-42 Ground strap, antenna:
Fuel supply tube assembly, Installation . . . . . . . . . . . . . . . . . . . . 12-136b 12-210
troop/cargo winterization heater: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-136a 12-209
Installation . . . . . . . . . . . . . . . . . . . . 12-83b 12-121 Gun adapter plate assembly:
Fuel system bleeding, heater. . . . . . 11-195 11-288 Removal . . . . . . . . . . . . . . . . . . . . . . . 11-95a 11-137
Fuel tank vent stack tube: Gun display unit battery strap (L119):
Gun mount plate assembly, front:
G Installation . . . . . . . . . . . . . . . . . . . . 11-96b 11-138
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-96a 11-138
Gas filter and bracket, NBC: Gun mount plate assembly, rear:
Installation . . . . . . . . . . . . . . . . . . . . 11-97b 11-139
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-167a 11-246 Gun mount support (caliber .50):
Gasoline cook stove bracket Installation . . . . . . . . . . . . . . . . . . . . 11-98b 11-140
assembly: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-98a 11-140
Installation . . . . . . . . . . . . . . . . . . . . 11-89b 11-131 Gun mount support (40 mm):
Gas spring, cargo shell door: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-99a 11-141
Assembly . . . . . . . . . . . . . . . . . . . . . . 11-21d 11-38 Gunner’s platform:
Disassembly . . . . . . . . . . . . . . . . . . . 11-21c 11-38 Installation . . . . . . . . . . . . . . . . . . . . 11-63b 11-84
Installation . . . . . . . . . . . . . . . . . . . . 11-21e 11-38 Removal . . . . . . . . . . . . . . . . . . . . . . . 11-63a 11-84
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-21b 11-37 Gunner’s platform assembly:
Rotating . . . . . . . . . . . . . . . . . . . . . . . 11-21a 11-35 Assembly . . . . . . . . . . . . . . . . . . . . . . 11-64b 11-88
Gas spring mounting bracket, Disassembly . . . . . . . . . . . . . . . . . . . 11-64a 11-86
cargo shell door: Installation . . . . . . . . . . . . . . . . . . . . 11-65b 11-90
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-29a 11-47 Gunner’s sling, hinge pivot
General instructions, preparation bracket and:
for stowage and shipment: Installation . . . . . . . . . . . . . . . . . . . . 11-52b 11-73
Administrative storage. . . . . . . . . 13-2 13-1 Removal . . . . . . . . . . . . . . . . . . . . . . . 11-52a 11-73
Cleaning. . . . . . . . . . . . . . . . . . . . . . . 13-6 13-2 Gunner’s sling hook:
General storage and shipping Installation . . . . . . . . . . . . . . . . . . . . 11-53b 11-74
information. . . . . . . . . . . . . . . . . . . 13-5 13-2 Removal . . . . . . . . . . . . . . . . . . . . . . . 11-53a 11-74
Inspections, stowage and
inventory . . . . . . . . . . . . . . . . . . . . . 13-7 13-2 H
Lubrication . . . . . . . . . . . . . . . . . . . . 13-9 13-3
Records and reports. . . . . . . . . . . . 13-10 13-3 Hand guard, ready rack:
Repair, printing, and Installation . . . . . . . . . . . . . . . . . . . . 12-155b 12-246
preservation . . . . . . . . . . . . . . . . . . 13-8 13-3 Removal . . . . . . . . . . . . . . . . . . . . . . . 12-155a 12-246
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1 13-1 Handle assembly, door:
Security . . . . . . . . . . . . . . . . . . . . . . . 13-3 13-1 Installation . . . . . . . . . . . . . . . . . . . . 10-13c 10-20
Special packaging and
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-13a 10-18
shipping requirements . . . . . . . . 13-4 13-1
Grab handle, cargo shell door: Repair . . . . . . . . . . . . . . . . . . . . . . . . . 10-13b 10-18
Installation . . . . . . . . . . . . . . . . . . . . 11-15b 11-27
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-15a 11-27
Change 1 INDEX 15
TM 9-2320-280-20-3
INDEX (Cont’d)
Para Page Para Page
H (Cont’d)
Handle assembly, troop/cargo Heater assembly:

winterization: Installation . . . . . . . . . . . . . . . . . . . . 10-87b 10-144
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-123a 12-195 Heater assembly, arctic:
Handle, cargo shell door grab: Installation . . . . . . . . . . . . . . . . . . . . 12-41b 12-60
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-15a 11-27 Heater assembly, troop/cargo
Handle latch, cargo shell door: winterization:
Installation . . . . . . . . . . . . . . . . . . . . 11-16b 11-28 Installation: . . . . . . . . . . . . . . . . . . . 12-95b 12-138
Handles, rear door: Heater base assembly,
Installation . . . . . . . . . . . . . . . . . . . . 11-127b 11-186 troop/cargo winterization:
Handset bracket: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-98a 12-142
Installation . . . . . . . . . . . . . . . . . . . . 12-143b 12-224 Heater boot:
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-143a 12-224 Installation . . . . . . . . . . . . . . . . . . . . 10-96b 10-164.1
Hatch handle, weapon station: Removal . . . . . . . . . . . . . . . . . . . . . . . 10-96a 10-164.1
Installation . . . . . . . . . . . . . . . . . . . . 11-43b 11-63 Heater brackets, NBC:
Hatch hinge pin, weapon station: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-165a 11-243
Installation . . . . . . . . . . . . . . . . . . . . 11-44b 11-64 Heater compartment panel
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-44a 11-64 (M996, M996A1):
Hatch hinge, weapon station: Installation . . . . . . . . . . . . . . . . . . . . 11-204b 11-309
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-45a 11-65 Heater control:
Hatch holddown striker, Installation . . . . . . . . . . . . . . . . . . . . 10-89b 10-148
weapon station: Removal . . . . . . . . . . . . . . . . . . . . . . . 10-89a 10-148
Installation . . . . . . . . . . . . . . . . . . . . 11-46b 11-67 Heater control box and angle
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-46a 11-67 bracket, troop/cargo
Hatch latch, weapon station: winterization:
Hatch tube assembly, weapon Heater control cable
station: and shutoff valve:
Installation . . . . . . . . . . . . . . . . . . . . 11-51b 11-72 Adjustment . . . . . . . . . . . . . . . . . . . . 10-90 10-150
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-51a 11-72 Heater ducting:
Hatch, weapon station: Installation . . . . . . . . . . . . . . . . . . . . 10-91b 10-152
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-42a 11-62 Heater exhaust pipe
Headphone mounting bracket: (M996, M996A1):
Heat/air-conditioning duct: Heater exhaust pipe
Assembly . . . . . . . . . . . . . . . . . . . . . . 11-211c 11-320 (M997, M997A1, M997A2):
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-211a 11-319 Heater fan motor resistor assembly:
Heat deflector, troop/cargo Installation . . . . . . . . . . . . . . . . . . . . 10-86b 10-142
winterization: Removal . . . . . . . . . . . . . . . . . . . . . . . 10-86a 10-142
Installation . . . . . . . . . . . . . . . . . . . . 12-94b 12-136 Heater fan switch:
Heater air intake assembly, Removal . . . . . . . . . . . . . . . . . . . . . . . 10-85a 10-140
troop/cargo winterization: Heater fuel filter:
INDEX 16 Change 1
TM 9-2320-280-20-3
INDEX (Cont’d)
Para Page Para Page
H (Cont’d)
Heater, fuel lines replacement: Heater wiring harness,
“B” beam fuel line. . . . . . . . . . . . . . 11-193d 11-282 troop/cargo winterization:
Bulkhead coupling . . . . . . . . . . . . . 11-193f 11-282 Installation . . . . . . . . . . . . . . . . . . . . 12-101b 12-148
Bulkhead fuel line . . . . . . . . . . . . . 11-193g 11-284 Removal . . . . . . . . . . . . . . . . . . . . . . . 12-101a 12-146
Cab fuel line . . . . . . . . . . . . . . . . . . . 11-193b 11-280 Hinge, ballistic crew door:
Filter fuel line . . . . . . . . . . . . . . . . . 11-193e 11-282 Installation . . . . . . . . . . . . . . . . . . . . 11-3b 11-8
Heater fuel line . . . . . . . . . . . . . . . . 11-193a 11-280 Removal . . . . . . . . . . . . . . . . . . . . . . . 11-3a 11-8
Pump fuel line . . . . . . . . . . . . . . . . . 11-193h 11-284 Hinge, hood:
Shutoff valve . . . . . . . . . . . . . . . . . . 11-193c 11-282 Alignment . . . . . . . . . . . . . . . . . . . . . 10-5c 10-10
Tank fuel line and supply tube . 11-193i 11-284 Installation . . . . . . . . . . . . . . . . . . . . 10-5b 10-8
Heater fuel pump: Removal . . . . . . . . . . . . . . . . . . . . . . . 10-5a 10-8
Installation . . . . . . . . . . . . . . . . . . . . 11-194b 11-286 Hinge pin, weapon station hatch:
Heater fuel system bleeding . . . . . . 11-195 11-288 Removal . . . . . . . . . . . . . . . . . . . . . . . 11-44a 11-64
Heater guard assembly, Hinge pivot bracket and
troop/cargo winterization: gunner’s sling:
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-93a 12-135
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-52a 11-73
Heater hose:
Installation . . . . . . . . . . . . . . . . . . . . 10-96.2b 10-164.4 Hinge, rear door:
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-96.2a 10-164.4 Installation . . . . . . . . . . . . . . . . . . . . 11-126b 11-185
Heater (M996, M996A1): Removal . . . . . . . . . . . . . . . . . . . . . . . 11-126a 11-185
Installation . . . . . . . . . . . . . . . . . . . . 11-209b 11-316 Hinge, rear steps:
Heater (M997, M997A1, M997A2): Removal . . . . . . . . . . . . . . . . . . . . . . . 11-133a 11-193
Installation . . . . . . . . . . . . . . . . . . . . 11-190b 11-274 Hinge, soft top door:
Heater mounting bracket Removal . . . . . . . . . . . . . . . . . . . . . . . 10-101a 10-170
assembly (M996, M996A1): Hinge, tailgate upper
Heater, NBC: Hinge, weapon station hatch:
Heater nozzle deflector: Holddown strike, engine access
Installation . . . . . . . . . . . . . . . . . . . . 10-94.1b 10-163 cover flexible latch and:
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-94.1a 10-163
Installation . . . . . . . . . . . . . . . . . . . . 10-16b 10-27
Heater outlet/blower fan hose
(M996, M996A1): Removal . . . . . . . . . . . . . . . . . . . . . . . 10-16a 10-27
Installation . . . . . . . . . . . . . . . . . . . . 11-206b 11-312 Holder assembly, rear door:
Heater outlet hose Removal . . . . . . . . . . . . . . . . . . . . . . . 11-132a 11-192
(M997, M997A1, M997A2): Hood and hinge:
Installation . . . . . . . . . . . . . . . . . . . . 11-191b 11-276 Alignment . . . . . . . . . . . . . . . . . . . . . 10-5c 10-10
Heater outlet/inlet piping: Removal . . . . . . . . . . . . . . . . . . . . . . . 10-5a 10-8
Inspection . . . . . . . . . . . . . . . . . . . . . 10-84b 10-138 Hood center armor plate:
Installation . . . . . . . . . . . . . . . . . . . . 10-84c 10-138 Installation . . . . . . . . . . . . . . . . . . . . 11-33b 11-52
Heater shutoff valve: Hood front armored grille:
Heater wiring harness adapter, Hood grille and screen:
troop/cargo winterization: Installation . . . . . . . . . . . . . . . . . . . . 10-12b 10-17
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-102a 12-150
Change 1 INDEX 17
TM 9-2320-280-20-3
INDEX (Cont’d)
Para Page Para Page
H (Cont’d) I
Hood latch and bracket: Illustrated list of manufactured items:
Assembly . . . . . . . . . . . . . . . . . . . . . . 10-3c 10-4 Appendix D . . . . . . . . . . . . . . . . . . . . D-1
Disassembly . . . . . . . . . . . . . . . . . . . 10-3b 10-4 Inclinometer, weapon station:
Hood prop rod and bracket: Insulation, arctic heater front cowl:
Assembly . . . . . . . . . . . . . . . . . . . . . . 10-4d 10-6 Installation . . . . . . . . . . . . . . . . . . . . 12-46b 12-68
Inspection . . . . . . . . . . . . . . . . . . . . . 10-4c 10-6 Insulation, left front cowl:
Installation . . . . . . . . . . . . . . . . . . . . 10-4e 10-7 Installation . . . . . . . . . . . . . . . . . . . . 10-26b 10-46
Hood screen, front: Insulation, left outer cowl:
Hood seal, outer: Insulation, panel:
Hood side armor plate: Insulation panel, cargo shell roof:
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-31a 11-50
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-32a 11-51
Insulation panel, left inner cowl:
Hood stop, center:
Installation . . . . . . . . . . . . . . . . . . . . 10-31b 10-54
Installation . . . . . . . . . . . . . . . . . . . . 10-8b 10-13
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-31a 10-52
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-8a 10-13
Insulation panel, right inner cowl:
Hood stop guide, center: Installation . . . . . . . . . . . . . . . . . . . . 10-30b 10-51
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-10a 10-15 Insulation, rear seat floor:
Hood stop, side: Installation . . . . . . . . . . . . . . . . . . . . 10-29b 10-50
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-7a 10-12 Insulation, right front cowl:
Hood top armored grille: Installation . . . . . . . . . . . . . . . . . . . . 10-27b 10-47
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-34a 11-53 Insulation strip, arctic foam:
Hook, gunner’s sling: Installation . . . . . . . . . . . . . . . . . . . . 12-79b 12-113
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-53a 11-74 Insulation, tunnel interior side:
Hook, IV bag: Installation . . . . . . . . . . . . . . . . . . . . 10-28b 10-48
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-150a 11-219 Intercom and brackets:
Hose, heater outlet Installation . . . . . . . . . . . . . . . . . . . . 11-169b 11-251
(M997, M997A1, M997A2): Removal . . . . . . . . . . . . . . . . . . . . . . . 11-169a 11-250
Installation . . . . . . . . . . . . . . . . . . . . 11-191b 11-277 IV bag hook:
Hose, heater outlet/blower fan Removal . . . . . . . . . . . . . . . . . . . . . . . 11-150a 11-219
(M996, M996A1): IV bag strap:
Hoses, windshield washer:
Installation . . . . . . . . . . . . . . . . . . . . 10-76b 10-126 J
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-76a 10-126
Housing, fuel filter: Jack retaining strap:
Installation . . . . . . . . . . . . . . . . . . . . 10-2b 10-3 Installation . . . . . . . . . . . . . . . . . . . . 10-9.1b 10-14.1
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-2a 10-3 Removal . . . . . . . . . . . . . . . . . . . . . . . 10-9.1a 10-14.1
Hydro-boost vent line: Jack stowage bracket and
Installation . . . . . . . . . . . . . . . . . . . . 12-11b 12-14 cover, 3.5-ton:
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-19a 10-33
INDEX 18 Change 1
TM 9-2320-280-20-3
INDEX (Cont’d)
Para Page Para Page
L
Lamp, troop/cargo winterization Launch tube stowage brackets:

blackout/dome light: Installation . . . . . . . . . . . . . . . . . . . . 11-87b 11-129
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-109a 12-161 Lever, weapon station tray:
Latch and bracket, hood: Installation . . . . . . . . . . . . . . . . . . . . 11-49b 11-70
Disassembly . . . . . . . . . . . . . . . . . . . 10-3b 10-4 Lifting shackle (L119),
Installation . . . . . . . . . . . . . . . . . . . . 10-3d 10-4 rear bumper:
Latch assembly and guide, Removal . . . . . . . . . . . . . . . . . . . . . . . 12-171a 12-264
rear door: Light assembly, troop/cargo
Installation . . . . . . . . . . . . . . . . . . . . 11-128b 11-187 winterization blackout/dome:
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-128a 11-187 Installation: . . . . . . . . . . . . . . . . . . . 12-108b 12-160
Latch assembly, rear steps: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-108a 12-160
Adjustment . . . . . . . . . . . . . . . . . . . . 11-135c 11-196 Light housing, troop/cargo
Installation . . . . . . . . . . . . . . . . . . . . 11-135b 11-196 winterization rear composite:
Latch, ballistic crew door: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-127a 12-199
Installation . . . . . . . . . . . . . . . . . . . . 11-11b 11-18 Liner, cargo shell door:
Latch, battery box cover: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-30a 11-48
Installation . . . . . . . . . . . . . . . . . . . . 10-36b 10-63 Linkage, windshield wiper:
Latch, bulkhead door: Removal . . . . . . . . . . . . . . . . . . . . . . . 10-73a 10-122
Installation . . . . . . . . . . . . . . . . . . . . 11-156b 11-230 Litter assembly, soft top
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-156a 11-228 ambulance:
Latch, cargo shell door: Assembly . . . . . . . . . . . . . . . . . . . . . . 11-124d 11-180
Adjustment . . . . . . . . . . . . . . . . . . . . 11-17c 11-29 Disassembly . . . . . . . . . . . . . . . . . . . 11-124b 11-178
Installation . . . . . . . . . . . . . . . . . . . . 11-17b 11-29 Inspection . . . . . . . . . . . . . . . . . . . . . 11-124c 11-178
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-17a 11-29 Installation . . . . . . . . . . . . . . . . . . . . 11-124e 11-182
Latch, cargo shell door handle: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-124a 11-176
Installation . . . . . . . . . . . . . . . . . . . . 11-16b 11-28 Litter handle bumper:
Latch, engine access cover flexible Removal . . . . . . . . . . . . . . . . . . . . . . . 11-147a 11-215
holddown strike: Litter rack latch bracket, upper:
Latch, NBC compartment door: Litter rack latch, upper:
Adjustment . . . . . . . . . . . . . . . . . . . . 11-142c 11-210
Installation . . . . . . . . . . . . . . . . . . . . 11-163b 11-241
Installation . . . . . . . . . . . . . . . . . . . . 11-142b 11-210
Latch, passenger seat stowage Litter rack strap and ring, upper:
compartment: Installation . . . . . . . . . . . . . . . . . . . . 11-145b 11-212.1
Installation . . . . . . . . . . . . . . . . . . . . 10-44b 10-72 Removal . . . . . . . . . . . . . . . . . . . . . . . 11-145a 11-212.1
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-44a 10-72 Litter rack striker support
Latch rod, cargo shell door: bracket, upper:
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-18a 11-30 Litter rack striker, upper:
Latch, upper litter rack: Installation . . . . . . . . . . . . . . . . . . . . 11-139b 11-206
Adjustment . . . . . . . . . . . . . . . . . . . . 11-142c 11-210 Removal . . . . . . . . . . . . . . . . . . . . . . . 11-139a 11-206
Installation . . . . . . . . . . . . . . . . . . . . 11-142b 11-210 Litter rack support bracket,
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-142a 11-210 upper:
Installation . . . . . . . . . . . . . . . . . . . . 11-144b 11-212
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-144a 11-212
Change 1 INDEX 19
TM 9-2320-280-20-3
INDEX (Cont’d)
Para Page Para Page
L (Cont’d)
Litter rack, upper: Mandatory replacement parts:
Installation . . . . . . . . . . . . . . . . . . . . 11-140b 11-207 Appendix G. . . . . . . . . . . . . . . . . . . . G-1
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-140a 11-207 Mat, ambulance compartment:
Litter rail extension: Installation . . . . . . . . . . . . . . . . . . . . 11-153b 11-222
Disassembly . . . . . . . . . . . . . . . . . . . 11-161a 11-238 Medical stowage cover and latch:
Litter skid pad: Installation . . . . . . . . . . . . . . . . . . . . 11-179b 11-261
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-146a 11-214 Mirror:
Litter skid tracks edge trim: Installation . . . . . . . . . . . . . . . . . . . . 10-79b 10-130
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-145.1a 11-212.2 Mirror arm assembly:
Litter stowage door: Installation . . . . . . . . . . . . . . . . . . . . 10-80b 10-131
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-159a 11-235 Mirror mounting bracket:
Litter stowage tray support
Installation . . . . . . . . . . . . . . . . . . . . 10-81b 10-132
and strap:
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-81a 10-132
Leg installation . . . . . . . . . . . . . . . . 11-160b 11-236
Mirror, rearview:
Leg removal . . . . . . . . . . . . . . . . . . . 11-160a 11-236
Straps installation . . . . . . . . . . . . . 11-160d 11-236 Assembly . . . . . . . . . . . . . . . . . . . . . . 10-82d 10-134
Straps removal . . . . . . . . . . . . . . . . 11-160c 11-236 Disassembly . . . . . . . . . . . . . . . . . . . 10-82c 10-134
Lock, ballistic crew door paddle: Inspection . . . . . . . . . . . . . . . . . . . . . 10-82b 10-133
Lock, cargo shell door wire Missile guidance set (MGS)
handle: battery rack assembly:
Lock, turret: Missile rack, TOW:
Installation . . . . . . . . . . . . . . . . . . . . 11-56b 11-77 Assembly . . . . . . . . . . . . . . . . . . . . . . 11-75d 11-112
Louver, air-conditioning duct: Inspection . . . . . . . . . . . . . . . . . . . . . 11-75c 11-110
Louver, floor heat duct: Mortar ammo container:
Installation . . . . . . . . . . . . . . . . . . . . 12-149d 12-239
M Removal . . . . . . . . . . . . . . . . . . . . . . . 12-149a 12-236
Mortar barrel stowage bracket:
M11 decontamination Installation . . . . . . . . . . . . . . . . . . . . 12-159b 12-250
brackets installation: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-159a 12-250
Installation . . . . . . . . . . . . . . . . . . . . 10-68 10-112 Mortar kit, 81 mm:
M16 ammo rack assembly: Maintenance task summary. . . . 12-148 12-235
Installation . . . . . . . . . . . . . . . . . . . . 11-74b 11-106 Motor and housing, blower:
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-74a 11-106 Blower housing installation . . . . 11-198d 11-292
Machine gun stop: Blower housing removal . . . . . . . 11-198c 11-292
Installation . . . . . . . . . . . . . . . . . . . . 11-100b 11-142 Blower motor installation . . . . . . 11-198f 11-294
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-100a 11-142 Blower motor removal . . . . . . . . . 11-198e 11-294
Machine gun strap (L119), M60: Closing blower housing . . . . . . . . 11-198b 11-292
Installation . . . . . . . . . . . . . . . . . . . . 12-182b 12-277 Opening blower housing . . . . . . . 11-198a 11-292
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-182a 12-277 Motor (SF5578716), windshield wiper:
Maintenance allocation chart: Installation . . . . . . . . . . . . . . . . . . . . 10-71b 10-118
Appendix B. . . . . . . . . . . . . . . . . . . . B-1 Removal . . . . . . . . . . . . . . . . . . . . . . . 10-71a 10-118
INDEX 20 Change 1
TM 9-2320-280-20-3
INDEX (Cont’d)
Para Page Para Page
M (Cont’d)
Motor (12342501), windshield Night sight mounting spacers

wiper/switch: or boresight collimator:
Mount adapter, traversing unit: Night sight retainer:
Assembly . . . . . . . . . . . . . . . . . . . . . . 11-72b 11-103 Installation . . . . . . . . . . . . . . . . . . . . 11-101b 11-143
Disassembly . . . . . . . . . . . . . . . . . . . 11-72a 11-103 Removal . . . . . . . . . . . . . . . . . . . . . . . 11-101a 11-143
Mount, body hinge: Night sight support:
Mud flap installation . . . . . . . . . . . . . 10-63 10-102 Nozzle, left defroster:
Installation . . . . . . . . . . . . . . . . . . . . 10-94b 10-162
N Removal . . . . . . . . . . . . . . . . . . . . . . . 10-94a 10-160
Nozzle, right defroster:
NBC air line piping: Installation . . . . . . . . . . . . . . . . . . . . 10-95b 10-164
Fabrication . . . . . . . . . . . . . . . . . . . . 11-166b 11-244 Removal . . . . . . . . . . . . . . . . . . . . . . . 10-95a 10-164
Installation . . . . . . . . . . . . . . . . . . . . 11-166c 11-244 Nozzle, windshield washer:
NBC compartment door latch: Removal . . . . . . . . . . . . . . . . . . . . . . . 10-78a 10-129
Installation . . . . . . . . . . . . . . . . . . . . 11-163b 11-241
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-163a 11-241 P
NBC compartment door
(M997, M997A1, M997A2): Padding, “B” pillar:
Installation . . . . . . . . . . . . . . . . . . . . 11-162b 11-240 Installation . . . . . . . . . . . . . . . . . . . . 11-30.1b 11-49
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-162a 11-240 Removal . . . . . . . . . . . . . . . . . . . . . . . 11-30.1a 11-49
NBC door (M996, M996A1): Paddle lock, ballistic crew door:
NBC gas filter and bracket: Pad, litter skid:
NBC heater: Pad, troop seat support:
NBC heater brackets: Panel, ambulatory patient
Installation . . . . . . . . . . . . . . . . . . . . 11-165b 11-243 seat rear closeout:
NBC precleaner, particulate, Removal . . . . . . . . . . . . . . . . . . . . . . . 11-182a 11-265
filter assembly, and bracket: Panel, cab enclosure:
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-122a 11-172
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-168a 11-248
Panel, front cover:
Net, stowage assembly: Installation . . . . . . . . . . . . . . . . . . . . 11-187b 11-271
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-173a 11-255 Panel insulation:
Night sight battery bracket, front: Installation . . . . . . . . . . . . . . . . . . . . 11-214b 11-324
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-84a 11-126 Panel (M996, M996A1), heater
Night sight battery bracket, rear: compartment:
Night sight coolant base: Panel, rear cover:
Change 1 INDEX 21
TM 9-2320-280-20-3
INDEX (Cont’d)
Para Page Para Page
P (Cont’d)
Panels, air intake compartment: Plate, ballistic crew door
Installation . . . . . . . . . . . . . . . . . . . . 11-184b 11-268 rear striker:
Pan, TOW Missile Guidance System: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-4a 11-9
Installation . . . . . . . . . . . . . . . . . . . . 11-59b 11-80 Plate, cargo shell door rear
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-59a 11-80 striker mounting:
Pedestal cover, TOW mount: Installation . . . . . . . . . . . . . . . . . . . . 11-27b 11-45
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-58a 11-79 Plate, driver’s seat retainer:
Pedestal, stowage: Installation . . . . . . . . . . . . . . . . . . . . 10-59b 10-95
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-71a 11-102 Platform assembly, gunner’s:
Pedestal, TOW mount: Installation . . . . . . . . . . . . . . . . . . . . 11-65b 11-90
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-57a 11-78 Platform assembly maintenance,
Pioneer tool stowage rack gunner’s:
latch striker (L119): Assembly . . . . . . . . . . . . . . . . . . . . . . 11-64c 11-86
Pioneer tool stowage tray: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-64a 11-86
Assembly . . . . . . . . . . . . . . . . . . . . . . 10-50b 10-84 Platform, gunner’s:
Disassembly . . . . . . . . . . . . . . . . . . . 10-50a 10-84 Installation . . . . . . . . . . . . . . . . . . . . 11-63b 11-84
Pioneer tool stowage tray Removal . . . . . . . . . . . . . . . . . . . . . . . 11-63a 11-84
latch striker: Plenum assembly, arctic heater:
Pioneer tool stowage tray Plenum cover, arctic heater:
mounting bracket: Installation . . . . . . . . . . . . . . . . . . . . 12-39b 12-57
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-51a 10-86 Plenum hose, arctic heater:
Piping, heater outlet/inlet: Installation . . . . . . . . . . . . . . . . . . . . 12-38b 12-56
Inspection . . . . . . . . . . . . . . . . . . . . . 10-84b 10-138 Removal . . . . . . . . . . . . . . . . . . . . . . . 12-38a 12-56
Installation . . . . . . . . . . . . . . . . . . . . 10-84c 10-138 Power cable, front radio rack:
Pivot, windshield wiper arm: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-141a 12-221
Installation . . . . . . . . . . . . . . . . . . . . 10-74b 10-123 Power steering vent line:
Placard, Red Cross: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-14a 12-17
Installation . . . . . . . . . . . . . . . . . . . . 11-175b 11-257 Precleaner and particulate filter
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-175a 11-257 assembly and bracket, NBC:
Plate assembly, front gun mount: Installation . . . . . . . . . . . . . . . . . . . . 11-168b 11-249
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-96a 11-138 Preparation for storage
Plate assembly, gun adapter: or shipment:
Installation . . . . . . . . . . . . . . . . . . . . 11-95b 11-137 Administrative storage. . . . . . . . . 13-2 13-1
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-95a 11-137 Cleaning. . . . . . . . . . . . . . . . . . . . . . . 13-6 13-2
Plate assembly, rear gun mount: General storage and
Installation . . . . . . . . . . . . . . . . . . . . 11-97b 11-139 shipping information. . . . . . . . . . 13-5 13-2
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-97a 11-139 Inspections, stowage,
Plate, ballistic crew door and inventory. . . . . . . . . . . . . . . . . 13-7 13-2
front striker: Lubrication . . . . . . . . . . . . . . . . . . . . 13-9 13-3
Adjustment . . . . . . . . . . . . . . . . . . . . 11-5c 11-10 Records and reports. . . . . . . . . . . . 13-10 13-3
Installation . . . . . . . . . . . . . . . . . . . . 11-5b 11-10 Repair, painting, and
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-5a 11-10 preservation . . . . . . . . . . . . . . . . . . 13-8 13-3
INDEX 22 Change 1
TM 9-2320-280-20-3
INDEX (Cont’d)
Para Page Para Page
P (Cont’d)
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1 13-1 Radio rack power cable, front:
Security . . . . . . . . . . . . . . . . . . . . . . . 13-3 13-1 Installation . . . . . . . . . . . . . . . . . . . . 12-141b 12-222
Special packaging and Removal . . . . . . . . . . . . . . . . . . . . . . . 12-141a 12-221
shipping requirements . . . . . . . . 13-4 13-1 Radio rack power cable, rear:
Prop rod and bracket, hood: Installation . . . . . . . . . . . . . . . . . . . . 12-147b 12-234
Assembly . . . . . . . . . . . . . . . . . . . . . . 10-4d 10-6 Removal . . . . . . . . . . . . . . . . . . . . . . . 12-147a 12-232
Disassembly . . . . . . . . . . . . . . . . . . . 10-4b 10-6 Radio rack, rear:
Inspection . . . . . . . . . . . . . . . . . . . . . 10-4c 10-6 Assembly . . . . . . . . . . . . . . . . . . . . . . 12-144c 12-226
Installation . . . . . . . . . . . . . . . . . . . . 10-4e 10-7 Disassembly . . . . . . . . . . . . . . . . . . . 12-144b 12-226
Pump assembly, windshield Removal . . . . . . . . . . . . . . . . . . . . . . . 12-144a 12-225
washer reservoir: Radio rack to tower
Installation . . . . . . . . . . . . . . . . . . . . 10-75b 10-124
antenna cables, rear:
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-75a 10-124
Installation . . . . . . . . . . . . . . . . . . . . 12-146b 12-230
R Removal . . . . . . . . . . . . . . . . . . . . . . . 12-146a 12-230
Rail, attendant seat guide:
Rack, equipment: Installation . . . . . . . . . . . . . . . . . . . . 11-158b 11-234
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-156a 12-247 Rail extension, litter:
Rack, ready: Assembly . . . . . . . . . . . . . . . . . . . . . . 11-161b 11-238
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-153a 12-244 Rail, rear drip:
Radio antenna mount Installation . . . . . . . . . . . . . . . . . . . . 11-170b 11-252
(M996, M996A1): Removal . . . . . . . . . . . . . . . . . . . . . . . 11-170a 11-252
Installation . . . . . . . . . . . . . . . . . . . . 11-171b 11-253 Ready rack:
Radio antenna mount Removal . . . . . . . . . . . . . . . . . . . . . . . 12-153a 12-244
(M997, M997A1, M997A2): Ready rack hand guard:
Radio rack antenna tower, rear: Ready rack strap:
Installation . . . . . . . . . . . . . . . . . . . . 12-145d 12-228 Rear seat stowage compartment
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-145a 12-228 net brackets:
Radio rack, front: Installation . . . . . . . . . . . . . . . . . . . . 11-110b 11-152
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-132a 12-204 Rear steps:
Radio rack, front lower: Assembly . . . . . . . . . . . . . . . . . . . . . . 11-138c 11-202.2
Installation . . . . . . . . . . . . . . . . . . . . 12-133b 12-206 Disassembly . . . . . . . . . . . . . . . . . . . 11-138b 11-202.2
Radio rack, front upper mounting Removal . . . . . . . . . . . . . . . . . . . . . . . 11-138a 11-202
brackets: Rear steps latch assembly:
Installation. . . . . . . . . . . . . . . . . . . . . 12-131.1b12-202.2 Adjustment . . . . . . . . . . . . . . . . . . . . 11-135c 11-196
Removal . . . . . . . . . . . . . . . . . . . . . . . . 12-131.1a12-202.2 Installation . . . . . . . . . . . . . . . . . . . . 11-135b 11-196
Radio rack mounting bracket, front: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-135a 11-196
Installation . . . . . . . . . . . . . . . . . . . . 12-130b 12-202 Rearview mirror:
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-130a 12-202 Assembly . . . . . . . . . . . . . . . . . . . . . . 10-82d 10-134
Radio rack, new configuration Disassembly . . . . . . . . . . . . . . . . . . . 10-82c 10-134
front bracket: Inspection . . . . . . . . . . . . . . . . . . . . . 10-82b 10-133
Installation. . . . . . . . . . . . . . . . . . . . . . 12-132.1b12-204.3 Installation . . . . . . . . . . . . . . . . . . . . 10-82e 10-136
Vehicle preparation . . . . . . . . . . . . . . 12-132.1a12-204.2 Removal . . . . . . . . . . . . . . . . . . . . . . . 10-82a 10-133
Change 1 INDEX 23
TM 9-2320-280-20-3
INDEX (Cont’d)
Para Page Para Page
R (Cont’d)
Red Cross placard: Rifle mounting clamp:
Red Cross placard retaining clip: Rifle mounting clamp bracket:
References: Rifle mounting clamp bracket
Appendix A. . . . . . . . . . . . . . . . . . . . A-1 (M16 A1 rifle/M203 grenade
Reflector, troop/cargo launcher):
winterization rear: Installation . . . . . . . . . . . . . . . . . . . . 11-93b 11-135
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-126a 12-198 Rifle support:
Regulator, arctic heater: Installation . . . . . . . . . . . . . . . . . . . . 11-90b 11-132
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-40a 12-58
Regulator, 100 ampere S
(R027096300):
Installation . . . . . . . . . . . . . . . . . . . . 12-21b 12-26 Screen, front hood:
Regulator, 100 ampere Removal . . . . . . . . . . . . . . . . . . . . . . . 10-11a 10-16
(12342944, N3106): Seal, airlift to hood:
Reinforcement bracket, exhaust: Seal, ballistic crew door:
Reinforcement, shelter support:
Seal, cargo shell door:
Installation . . . . . . . . . . . . . . . . . . . . 11-115b 11-162
Installation . . . . . . . . . . . . . . . . . . . . 11-24b 11-42
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-115a 11-162
Reservoir and pump assembly, Removal . . . . . . . . . . . . . . . . . . . . . . . 11-24a 11-42
windshield washer: Seal, outer hood:
Resistor assembly, heater Seal protector, cargo shell door:
fan motor: Installation . . . . . . . . . . . . . . . . . . . . 11-23b 11-41
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-86a 10-142 Seal protector, rear door:
Resistor, blower motor: Installation . . . . . . . . . . . . . . . . . . . . 11-129b 11-188
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-197a 11-291 Seals, rear door:
Retainer, night sight: Installation . . . . . . . . . . . . . . . . . . . . 11-130b 11-189
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-101a 11-143 Seal, weapon station tray:
Retaining cable, rear steps: Installation . . . . . . . . . . . . . . . . . . . . 11-47b 11-68
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-136a 11-198 Seat, ambulatory patient:
Retention cable, cargo shell door: Installation . . . . . . . . . . . . . . . . . . . . 11-181b 11-264
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-20a 11-34 Seat assembly, companion:
Retractor, rear steps: Assembly . . . . . . . . . . . . . . . . . . . . . . 10-42b 10-70
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-137a 11-200 Seat assembly, companion and
Rifle mount bracket, lower: battery box cover:
INDEX 24 Change 1
TM 9-2320-280-20-3
INDEX (Cont’d)
Para Page Para Page
S (Cont’d)
Seat assembly, driver’s: Seatbelt, three point (M996,
Assembly . . . . . . . . . . . . . . . . . . . . . . 10-39b 10-66 M996A1, M997, M997A1, and
Disassembly . . . . . . . . . . . . . . . . . . . 10-39a 10-66 M997A2):
Installation . . . . . . . . . . . . . . . . . . . . 10-38b 10-65 Bracket inspection . . . . . . . . . . . . 10-48.1b 10-80.2
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-38a 10-65 Seatbelt installation . . . . . . . . . . 10-48.1c 10-80.2
Seat, attendant: Seatbelt removal. . . . . . . . . . . . . . 10-48.1a 10-80.2
Assembly . . . . . . . . . . . . . . . . . . . . . . 11-157c 11-232
Disassembly . . . . . . . . . . . . . . . . . . . 11-157b 11-232 Seat board, troop:
Seat back, companion: Seat, companion and battery
Installation . . . . . . . . . . . . . . . . . . . . 10-34b 10-61 box cover:
Seat back cover, troop/cargo Removal . . . . . . . . . . . . . . . . . . . . . . . 10-35a 10-62
winterization: Seat guide rail, attendant:
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-112a 12-165
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-158a 11-234
Seat back cushions,
companion seat: Seat kit, troop:
Installation . . . . . . . . . . . . . . . . . . . . 10-37b 10-64 Maintenance task summary. . . . 12-16 12-19
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-37a 10-64 Seat kit, troop:
Seat back cushions, Installation . . . . . . . . . . . . . . . . . . . . 12-18b 12-20
passenger seat: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-18a 12-20
Installation . . . . . . . . . . . . . . . . . . . . 10-46b 10-74 Seat rear close out panel,
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-46a 10-74 ambulatory patient:
Seat back, passenger: Installation . . . . . . . . . . . . . . . . . . . . 11-182b 11-265
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-45a 10-73
Seatbelt assembly: Seat stowage brackets, attendant:
Seatbelt brackets, three point: Seat support:
Front seatbelt bracket Installation . . . . . . . . . . . . . . . . . . . . 12-17b 12-19
installation . . . . . . . . . . . . . . . . . . . 10-49b 10-82 Removal . . . . . . . . . . . . . . . . . . . . . . . 12-17a 12-19
Front seatbelt bracket Seat support pad, troop:
removal . . . . . . . . . . . . . . . . . . . . . . 10-49a 10-82 Installation . . . . . . . . . . . . . . . . . . . . 12-158b 12-249
Rear seatbelt bracket Removal . . . . . . . . . . . . . . . . . . . . . . . 12-158a 12-249
installation . . . . . . . . . . . . . . . . . . . 10-49d 10-82
Section chest strap (L119):
Rear seatbelt bracket
removal . . . . . . . . . . . . . . . . . . . . . . 10-49c 10-82 Installation . . . . . . . . . . . . . . . . . . . . 12-176b 12-269
Seatbelt brackets, three point: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-176a 12-269
(M996, M996A1, M997, M997A1, Selector valve:
and M997A2): Installation . . . . . . . . . . . . . . . . . . . . 12-9b 12-11
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-49.1a 10-82.2 Sensor cup, deep water fording:
Seatbelt maintenance, three point: Installation . . . . . . . . . . . . . . . . . . . . 12-12b 12-15
Front seatbelt bracket Removal . . . . . . . . . . . . . . . . . . . . . . . 12-12a 12-15
inspection . . . . . . . . . . . . . . . . . . . . 10-48b 10-78 Sensor cup vent line:
Front seatbelt installation . . . . . 10-48c 10-78
Installation . . . . . . . . . . . . . . . . . . . . 12-13b 12-16
Front seatbelt removal . . . . . . . . . 10-48a 10-76
Rear seatbelt bracket Removal . . . . . . . . . . . . . . . . . . . . . . . 12-13a 12-16
inspection . . . . . . . . . . . . . . . . . . . . 10-48e 10-80 Shelf, auxiliary:
Rear seatbelt installation . . . . . . 10-48f 10-80 Installation . . . . . . . . . . . . . . . . . . . . 12-131b 12-203
Rear seatbelt removal. . . . . . . . . . 10-48d 10-80 Removal . . . . . . . . . . . . . . . . . . . . . . . 12-131a 12-203
Change 1 INDEX 25
TM 9-2320-280-20-3
INDEX (Cont’d)
Para Page Para Page
S (Cont’d)
Shelter: Skid strips, troop/cargo
Installation . . . . . . . . . . . . . . . . . . . . 11-120b 11-168 winterization cargo floor:
S250 shelter carrier body: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-111a 12-164
Maintenance task summary. . . . 11-114 11-161 Soft top door:
Shelter carrier tailgate: Adjustment . . . . . . . . . . . . . . . . . . . . 10-102 10-172
Installation . . . . . . . . . . . . . . . . . . . . 11-117b 11-164 Soft top door handle:
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-117a 11-164 Installation . . . . . . . . . . . . . . . . . . . . 10-102.1c 10-172.3
Shelter carrier tailgate bracket: Removal . . . . . . . . . . . . . . . . . . . . . . . . 10-102.1a 10-172.1
Installation . . . . . . . . . . . . . . . . . . . . 11-118b 11-165 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 10-102.1b10-172.2
Soft top door hinge:
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-118a 11-165
Installation . . . . . . . . . . . . . . . . . . . . 10-101b 10-170
Shelter carrier tailgate chain:
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-101a 10-170
Assembly . . . . . . . . . . . . . . . . . . . . . . 11-119c 11-166
Soft top door striker:
Disassembly . . . . . . . . . . . . . . . . . . . 11-119b 11-166
Shelter mounting bracket: Soft top repair:
Installation . . . . . . . . . . . . . . . . . . . . 11-116b 11-163 Inspection and cleaning . . . . . . . . 10-104a 10-175
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-116a 11-163 Soft top canvas repair . . . . . . . . . 10-104e 10-176.1
Shelter support assembly: Soft top material repair . . . . . . . . 10-104b 10-175
Installation . . . . . . . . . . . . . . . . . . . . 11-121b 11-170 Soft top window repair . . . . . . . . . 10-104c 10-176
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-121a 11-170 Soft top window zipper repair . . . 10-104d 10-176
Shelter support reinforcement: Speaker stop:
Shield, antenna blast: Spineboard mounting bracket:
Shutoff valve, heater: Splash shield, left, engine:
Sight box straps (L119): Installation . . . . . . . . . . . . . . . . . . . . 10-17d 10-30
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-179a 12-272 Splash shield, right, engine:
Siren and warning light Assembly . . . . . . . . . . . . . . . . . . . . . . 10-20c 10-36
installation: Disassembly . . . . . . . . . . . . . . . . . . . 10-20b 10-34
Circuit breaker and relay Installation . . . . . . . . . . . . . . . . . . . . 10-20d 10-36
installation . . . . . . . . . . . . . . . . . . . 12-185d 12-285 Removal . . . . . . . . . . . . . . . . . . . . . . . 10-20a 10-34
Manufactured items . . . . . . . . . . . 12-185a 12-282 Spreader bar tiedown:
Passenger’s side siren switch Installation . . . . . . . . . . . . . . . . . . . . 11-180.1b 11-262.1
and driver’s side siren Removal . . . . . . . . . . . . . . . . . . . . . . . . 11-180.1a 11-262.1
switch installation . . . . . . . . . . . . 12-185g 12-288 Spring, cargo shell door dovetail:
Siren and warning light Installation . . . . . . . . . . . . . . . . . . . . 11-28b 11-46
switch and indicator Removal . . . . . . . . . . . . . . . . . . . . . . . 11-28a 11-46
installation . . . . . . . . . . . . . . . . . . . 12-185e 12-286 Spring, cargo shell door gas:
Siren assembly installation . . . . 12-185c 12-284 Assembly . . . . . . . . . . . . . . . . . . . . . . 11-21d 11-38
Siren battery wires Disassembly . . . . . . . . . . . . . . . . . . . 11-21c 11-38
installation . . . . . . . . . . . . . . . . . . . 12-185i 12-292 Installation . . . . . . . . . . . . . . . . . . . . 11-21e 11-38
Siren electrical wires Removal . . . . . . . . . . . . . . . . . . . . . . . 11-21b 11-37
installation . . . . . . . . . . . . . . . . . . . 12-185f 12-287 Rotating . . . . . . . . . . . . . . . . . . . . . . . 11-21a 11-35
Warning light assembly Step assembly, troop/cargo
electrical wires installation . . . 12-185h 12-290 winterization rear:
Warning light assembly Installation . . . . . . . . . . . . . . . . . . . . 12-122b 12-194
installation . . . . . . . . . . . . . . . . . . . 12-185b 12-283 Removal . . . . . . . . . . . . . . . . . . . . . . 12-122a 12-194
INDEX 26 Change 1
TM 9-2320-280-20-3
INDEX (Cont’d)
Para Page Para Page
S (Cont’d)
Steps, rear: Stowage brackets, attendant seat:
Assembly . . . . . . . . . . . . . . . . . . . . . . 11-138c 11-202.2 Installation . . . . . . . . . . . . . . . . . . . . 11-177b 11-259
Disassembly . . . . . . . . . . . . . . . . . . . 11-138b 11-202.2 Removal . . . . . . . . . . . . . . . . . . . . . . . 11-177a 11-259
Installation . . . . . . . . . . . . . . . . . . . . 11-138d 11-204 Stowage bracket, launch tube:
Stop assembly, elevation Removal . . . . . . . . . . . . . . . . . . . . . . . 11-87a 11-129
and depression: Stowage bracket, mortar barrel:
Assembly . . . . . . . . . . . . . . . . . . . . . . 11-73b 11-104 Installation . . . . . . . . . . . . . . . . . . . . 12-159b 12-250
Disassembly . . . . . . . . . . . . . . . . . . . 11-73a 11-104 Removal . . . . . . . . . . . . . . . . . . . . . . . 12-159a 12-250
Stop, ballistic crew door window: Stowage clip, cleaning staff:
Installation . . . . . . . . . . . . . . . . . . . . 12-151b 12-241
Installation . . . . . . . . . . . . . . . . . . . . 11-9b 11-16
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-151a 12-241
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-9a 11-16
Stowage compartment latch,
Stop, center hood: passenger seat:
Stop guide, center hood: Stowage compartment net
Installation . . . . . . . . . . . . . . . . . . . . 10-10b 10-15 brackets, rear seat:
Stop, machine gun: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-110a 11-152
Installation . . . . . . . . . . . . . . . . . . . . 11-100b 11-142 Stowage door:
Stop, side hood: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-152a 11-221
Installation . . . . . . . . . . . . . . . . . . . . 10-7b 10-12 Stowage door, exterior:
Stop, speaker: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-176a 11-258
Installation . . . . . . . . . . . . . . . . . . . . 12-135b 12-208 Stowage mount bracket:
Storage and/or shipment, Removal . . . . . . . . . . . . . . . . . . . . . . . 11-70a 11-100
preparation for: Stowage net assembly:
Administrative storage. . . . . . . . . 13-2 13-1 Installation . . . . . . . . . . . . . . . . . . . . 11-173b 11-255
Cleaning. . . . . . . . . . . . . . . . . . . . . . . 13-6 13-2 Removal . . . . . . . . . . . . . . . . . . . . . . . 11-173a 11-255
General storage and Stowage pedestal:
shipping information. . . . . . . . . . 13-5 13-2 Installation . . . . . . . . . . . . . . . . . . . . 11-71b 11-102
Inspections, stowage, Removal . . . . . . . . . . . . . . . . . . . . . . . 11-71a 11-102
and inventory. . . . . . . . . . . . . . . . . 13-7 13-2 Stowage tray, bipod:
Assembly . . . . . . . . . . . . . . . . . . . . . . 12-152c 12-242
Lubrication . . . . . . . . . . . . . . . . . . . . 13-9 13-3
Disassembly . . . . . . . . . . . . . . . . . . . 12-152b 12-242
Records and reports. . . . . . . . . . . . 13-10 13-3
Installation . . . . . . . . . . . . . . . . . . . . 12-152d 12-242
Repair, painting, and Removal . . . . . . . . . . . . . . . . . . . . . . . 12-152a 12-242
preservation . . . . . . . . . . . . . . . . . . 13-8 13-3 Strap and ring, upper litter rack:
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1 13-1 Installation . . . . . . . . . . . . . . . . . . . . 11-145b 11-213
Security . . . . . . . . . . . . . . . . . . . . . . . 13-3 13-1 Removal . . . . . . . . . . . . . . . . . . . . . . . 11-145a 11-213
Special packaging and Strap, base plate:
shipping requirements . . . . . . . . 13-4 13-1 Installation . . . . . . . . . . . . . . . . . . . . 12-150b 12-240
Storage compartment cover, Removal . . . . . . . . . . . . . . . . . . . . . . . 12-150a 12-240
passenger seat: Strap, cargo shell door:
Stowage box turnbutton: Strap, footman loop:
Stowage bracket, day sight: Strap, IV bag:
Change 1 INDEX 27
TM 9-2320-280-20-3
INDEX (Cont’d)
Para Page Para Page
S (Cont’d)
Strap, jack retaining: Support assembly, shelter:
Installtion . . . . . . . . . . . . . . . . . . . 10-9.1b 10-14.1 Installation . . . . . . . . . . . . . . . . . . . . 11-121b 11-170
Removal . . . . . . . . . . . . . . . . . . . . . 10-9.1a 10-14.1 Removal . . . . . . . . . . . . . . . . . . . . . . . 11-121a 11-170
Strap, ready rack: Support (caliber .50), gun
Installation . . . . . . . . . . . . . . . . . . . . 12-154b 12-245 mount:
Strap, tool chest: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-98a 11-140
Installation . . . . . . . . . . . . . . . . . . . . 12-157b 12-248 Support, fire extinguisher:
Striker and bracket, rear steps: Removal . . . . . . . . . . . . . . . . . . . . . . . 10-58a 10-94
Bracket adjustment . . . . . . . . . . . . 11-134e 11-194 Support (40 mm), gun mount:
Bracket installation. . . . . . . . . . . . 11-134d 11-194 Installation . . . . . . . . . . . . . . . . . . . . 11-99b 11-141
Bracket removal . . . . . . . . . . . . . . . 11-134c 11-194 Removal . . . . . . . . . . . . . . . . . . . . . . . 11-99a 11-141
Striker installation . . . . . . . . . . . . 11-134b 11-194 Support, night sight:
Striker removal . . . . . . . . . . . . . . . . 11-134a 11-194 Installation . . . . . . . . . . . . . . . . . . . . 11-82b 11-124
Striker, cargo shell door, front: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-82a 11-124
Installation . . . . . . . . . . . . . . . . . . . . 11-25b 11-43 Support, rifle:
Striker, cargo shell door, rear: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-90a 11-132
Installation . . . . . . . . . . . . . . . . . . . . 11-26b 11-44 Support, seat:
Striker guides and brackets, Removal . . . . . . . . . . . . . . . . . . . . . . . 12-17a 12-19
rear door latch rod: Swingfire circuit breaker
Bracket installation. . . . . . . . . . . . 11-131d 11-190 and harness lead:
Bracket removal . . . . . . . . . . . . . . . 11-131c 11-190 Installation . . . . . . . . . . . . . . . . . . . . 12-69b 12-102
Striker guide adjustment . . . . . . 11-131e 11-190 Removal . . . . . . . . . . . . . . . . . . . . . . . 12-69a 12-102
Striker guide installation . . . . . . 11-131b 11-190 Swingfire heater brushguard
Striker guide removal . . . . . . . . . . 11-131a 11-190 and shield assembly:
Striker, pioneer tool stowage Installation . . . . . . . . . . . . . . . . . . . . 12-59b 12-86
tray latch: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-59a 12-86
Installation . . . . . . . . . . . . . . . . . . . . 10-52b 10-87 Swingfire heater exhaust
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-52a 10-87 pipe assembly:
Striker plate, ballistic crew door, Installation . . . . . . . . . . . . . . . . . . . . 12-60b 12-87
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-60a 12-87
front:
Swingfire heater harness
Adjustment . . . . . . . . . . . . . . . . . . . . 11-5c 11-10
assembly:
Installation . . . . . . . . . . . . . . . . . . . . 11-5b 11-10
Installation . . . . . . . . . . . . . . . . . . . . 12-68b 12-100
Striker plate, ballistic crew door, Swingfire heater hood guard:
rear: Installation . . . . . . . . . . . . . . . . . . . . 12-62b 12-89
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-4a 11-9 Swingfire heater inlet hose and tee:
Striker, upper litter rack: Installation . . . . . . . . . . . . . . . . . . . . 12-64b 12-92
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-139a 11-206 Swingfire heater pump assembly,
Striker, weapon station bracket, and lower hose:
hatch holddown: Installation . . . . . . . . . . . . . . . . . . . . 12-65b 12-94
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-46a 11-67 Swingfire heater radiator
Sun visor: lower tube:
Support and strap, litter Swingfire heater U-clamps:
storage tray: Installation . . . . . . . . . . . . . . . . . . . . 12-58b 12-85
Leg installation . . . . . . . . . . . . . . . . 11-160b 11-236 Removal . . . . . . . . . . . . . . . . . . . . . . . 12-58a 12-85
Leg removal . . . . . . . . . . . . . . . . . . . 11-160a 11-236 Swingfire heater water jacket:
Straps installation . . . . . . . . . . . . . 11-160d 11-236 Installation . . . . . . . . . . . . . . . . . . . . 12-57b 12-84
Straps removal . . . . . . . . . . . . . . . . 11-160c 11-236 Removal . . . . . . . . . . . . . . . . . . . . . . . 12-57a 12-83
INDEX 28 Change 1
TM 9-2320-280-20-3
INDEX (Cont’d)
Para Page Para Page
S (Cont’d)
Swingfire heater water jacket Tailgate chain, shelter carrier:
to pump and tee hoses: Assembly . . . . . . . . . . . . . . . . . . . . . . 11-119c 11-166
Swingfire heater windshield Removal . . . . . . . . . . . . . . . . . . . . . . . 11-119a 11-166
washer reservoir plate: Tailgate, shelter carrier:
Swingfire relay and harness Tailgate upper hinge:
assembly: Installation . . . . . . . . . . . . . . . . . . . . 10-62b 10-100
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-67a 12-97 Tape hook, arctic curtain fastener:
Swingfire windshield washer Installation . . . . . . . . . . . . . . . . . . . . 12-78b 12-112
pump harness extension: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-78a 12-112
Installation . . . . . . . . . . . . . . . . . . . . 12-70b 12-103 Telephone strap (L119):
Switch, heater fan: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-175a 12-268
Installation . . . . . . . . . . . . . . . . . . . . 10-85b 10-140 Three point seatbelt brackets:
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-85a 10-140 Front seatbelt bracket
Switch, troop/cargo winterization installation . . . . . . . . . . . . . . . . . . . 10-49b 10-82
blackout/dome light: Front seatbelt bracket
Installation . . . . . . . . . . . . . . . . . . . . 12-106b 12-156 removal . . . . . . . . . . . . . . . . . . . . . . 10-49a 10-82
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-106a 12-156 Rear seatbelt bracket
Switch, troop/cargo winterization installation . . . . . . . . . . . . . . . . . . . 10-49d 10-82
blackout/dome light door: Rear seatbelt bracket
Installation . . . . . . . . . . . . . . . . . . . . 12-107b 12-158 removal . . . . . . . . . . . . . . . . . . . . . . 10-49c 10-82
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-107a 12-158
Three point seatbelt brackets
(M996, M996A1, M997, M997A1,
T and M997A2):
Installation . . . . . . . . . . . . . . . . . . . . 10-49.1b 10-82.2
Tables: Removal . . . . . . . . . . . . . . . . . . . . . . . 10-49.1a 10-82.2
Countersinking dimensions Three point seatbelt:
for 100° countersunk blind Front seatbelt bracket
rivets (table 10-3) . . . . . . . . . . . . . . 10-66 10-108 inspection . . . . . . . . . . . . . . . . . . . . 10-48b 10-78
Drill sizes for blind rivets Front seatbelt installation . . . . . 10-48c 10-78
(table 10-2) . . . . . . . . . . . . . . . . . . . . 10-66 10-107 Front seatbelt removal . . . . . . . . . 10-48a 10-76
Drill sizes for solid shank Rear seatbelt bracket
rivets (table 10-1) . . . . . . . . . . . . . . 10-66 10-107 inspection . . . . . . . . . . . . . . . . . . . . 10-48e 10-80
Minimum sheet gauge for Rear seatbelt installation . . . . . . 10-48f 10-80
100° machine countersink Rear seatbelt removal. . . . . . . . . . 10-48d 10-80
(table 10-4). . . . . . . . . . . . . . . . . . . . . . . 10-66 10-108 Three point seatbelt (M996,
Rivet grip length M996A1, M997, M997A1,
determination (table 10-5). . . . . . 10-66 10-109 and M997A2):
Tailgate: Bracket inspection . . . . . . . . . . . . . 10-48.1b 10-80.2
Installation . . . . . . . . . . . . . . . . . . . . 10-61b 10-98 Seatbelt installation . . . . . . . . . . . 10-48.1c 10-80.2
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-61a 10-98 Seatbelt removal. . . . . . . . . . . . . . . 10-48.1a 10-80.2
Tailgate armor plate: Tiedown bracket (L119), rear:
Tailgate bracket, shelter carrier: Tiedown, cargo:
Tailgate chain and brackets: Tiedown, spreader bar:
Installation . . . . . . . . . . . . . . . . . . . . 10-60b 10-96 Installation . . . . . . . . . . . . . . . . . . 11-180.1b 11-262.1
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-60a 10-96 Removal . . . . . . . . . . . . . . . . . . . . . 11-180.1a 11-262.1
Change 1 INDEX 29
TM 9-2320-280-20-3
INDEX (Cont’d)
Para Page Para Page
T
Tool chest strap: Tray, pioneer tool stowage:
Installation . . . . . . . . . . . . . . . . . . . . 12-157b 12-248 Assembly . . . . . . . . . . . . . . . . . . . . . . 10-50b 10-84
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-157a 12-248 Disassembly . . . . . . . . . . . . . . . . . . . 10-50a 10-84
Torque limits: Tray, water can:
Appendix E . . . . . . . . . . . . . . . . . . . . E-1 Installation . . . . . . . . . . . . . . . . . . . . 11-108b 11-150
TOW missile guidance system pan: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-108a 11-150
Installation . . . . . . . . . . . . . . . . . . . . 11-59b 11-80 Tripod bracket:
TOW missile rack: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-102a 11-144
Assembly . . . . . . . . . . . . . . . . . . . . . . 11-75d 11-112 Tripod head mounting bracket:
Inspection . . . . . . . . . . . . . . . . . . . . . 11-75c 11-110 Removal . . . . . . . . . . . . . . . . . . . . . . . 11-79a 11-121
Installation . . . . . . . . . . . . . . . . . . . . 11-75e 11-116 Tripod leg mounting bracket:
TOW mount pedestal: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-78a 11-120
Installation . . . . . . . . . . . . . . . . . . . . 11-57b 11-78 Tripod strap (L119):
TOW mount pedestal cover: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-177a 12-270
Installation . . . . . . . . . . . . . . . . . . . . 11-58b 11-79 Troop/cargo winterization
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-58a 11-79 antenna mounting bracket:
TOW wiring harness: Installation . . . . . . . . . . . . . . . . . . . . 12-125b 12-197
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-67a 11-92 Troop/cargo winterization
Traversing bar kit: blackout curtain:
Maintenance task summary. . . . 12-160 12-251 Installation . . . . . . . . . . . . . . . . . . . . 12-104b 12-153
Traversing bar kit: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-104a 12-153
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-161a 12-252 blackout/dome light assembly:
Traversing unit mount adapter: Installation . . . . . . . . . . . . . . . . . . . . 12-108b 12-160
Disassembly . . . . . . . . . . . . . . . . . . . 11-72a 11-103 Troop/cargo winterization
Tray and bearing seals, blackout/dome light
weapon station: door switch:
Tray and hose, fuel can: blackout/dome light lamp:
Tray (caliber .50), ammo box: Troop/cargo winterization
Installation . . . . . . . . . . . . . . . . . . . . 11-104b 11-146 blackout/dome light switch:
Tray (caliber .50), double ammo box: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-106a 12-156
Installation . . . . . . . . . . . . . . . . . . . . 11-103b 11-145 Troop/cargo winterization blackout/
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-103a 11-145 dome light wiring harness:
Tray (40 mm and .50 caliber), Installation . . . . . . . . . . . . . . . . . . . . 12-105b 12-154
ammo box: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-105a 12-154
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-105a 11-147 cargo floor skid strips:
Tray (40 mm), double ammo box: Installation . . . . . . . . . . . . . . . . . . . . 12-111b 12-164
Tray (40 mm), triple ammo box: circuit breaker:
INDEX 30 Change 1
TM 9-2320-280-20-3
INDEX (Cont’d)
Para Page Para Page
T (Cont’d)
Troop/cargo winterization Troop/cargo winterization heater
data plate: bulkhead hose-to-bulkhead
Installation . . . . . . . . . . . . . . . . . . . . 12-128b 12-200 coupling fuel supply line:
Troop/cargo winterization door: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-89a 12-128
Adjustment . . . . . . . . . . . . . . . . . . . . 12-116 12-170 Troop/cargo winterization
Troop/cargo winterization heater control box and
door and frame assembly: angle bracket:
Troop/cargo winterization Troop/cargo winterization
end closure: heater diverter assembly:
Installation . . . . . . . . . . . . . . . . . . . 12-118b 12-178 Installation . . . . . . . . . . . . . . . . . . . . 12-96b 12-140
Troop/cargo winterization Troop/cargo winterization
fixed door cover: heater filter-to-bulkhead
Installation . . . . . . . . . . . . . . . . . . . . 12-113b 12-166 coupling fuel supply hose:
Troop/cargo winterization Removal . . . . . . . . . . . . . . . . . . . . . . . 12-91a 12-131
floor bracket: Troop/cargo winterization heater
Installation . . . . . . . . . . . . . . . . . . . . 12-99b 12-143 filter-to-heater fuel supply hose:
front and rear cargo floor cover: Troop/cargo winterization
Installation . . . . . . . . . . . . . . . . . . . . 12-110b 12-162 heater fuel filter assembly:
fuel can mounting bracket: Troop/cargo winterization
Installation . . . . . . . . . . . . . . . . . . . . 12-124b 12-196 heater fuel pump:
handle assembly: Troop/cargo winterization
Installation . . . . . . . . . . . . . . . . . . . . 12-123b 12-195 heater fuel supply hose:
heat deflector:
Troop/cargo winterization
Installation . . . . . . . . . . . . . . . . . . . . 12-94b 12-136
heater fuel supply line
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-94a 12-136
bulkhead coupling:
Installation . . . . . . . . . . . . . . . . . . . . 12-90b 12-130
heater air intake assembly:
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-97a 12-141
heater fuel supply tube
Troop/cargo winterization assembly:
heater assembly: Installation . . . . . . . . . . . . . . . . . . . . 12-83b 12-121
Troop/cargo winterization heater guard assembly:
heater base assembly: Installation . . . . . . . . . . . . . . . . . . . . 12-93b 12-135
Troop/cargo winterization heater heater pump-to-bulkhead
bulkhead fuel supply hose: fuel supply line:
Change 1 INDEX 31
TM 9-2320-280-20-3
INDEX (Cont’d)
Para Page Para Page
T (Cont’d)
Troop/cargo winterization Troop seat board:
heater pump-to-hose fuel Installation . . . . . . . . . . . . . . . . . . . . 12-19b 12-22
supply line: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-19a 12-22
Installation . . . . . . . . . . . . . . . . . . . . 12-86b 12-124 Troop seat kit:
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-86a 12-124 Maintenance task summary. . . . 12-16 12-19
Troop/cargo winterization Troop seat kit:
heater tank-to-hose fuel Installation . . . . . . . . . . . . . . . . . . . . 12-20b 12-20
supply line: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-20a 12-20
Installation . . . . . . . . . . . . . . . . . . . . 12-84b 12-122 Troop seat support pad:
heater wiring harness: TSEC/KY-57 mounting bracket
Installation . . . . . . . . . . . . . . . . . . . . 12-101b 12-148 and control switch bracket, dual:
heater wiring harness Tube, ballistic crew door latch:
adapter: Installation . . . . . . . . . . . . . . . . . . . . 11-12b 11-19
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-102a 12-150 Tube, evaporator drain:
Troop/cargo winterization kit: Installation . . . . . . . . . . . . . . . . . . . . 11-200b 11-302
Maintenance task summary. . . . 12-80 12-114 Removal . . . . . . . . . . . . . . . . . . . . . . . 11-200a 11-302
Troop/cargo winterization Tube, fuel tank vent stack:
rear composite light housing: Installation . . . . . . . . . . . . . . . . . . . . 12-8b 12-10
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-127a 12-199 Tunnel interior side insulation:
Troop/cargo winterization Installation . . . . . . . . . . . . . . . . . . . . 10-28b 10-48
rear reflector: Removal . . . . . . . . . . . . . . . . . . . . . . . 10-28a 10-48
Installation . . . . . . . . . . . . . . . . . . . . 12-126b 12-198 Turnbutton, stowage box:
rear step assembly: Turret bearing:
Installation . . . . . . . . . . . . . . . . . . . . 12-122b 12-194 Cleaning and inspection. . . . . . . . 11-113c 11-159
seat back cover: Turret cleaning:
Installation . . . . . . . . . . . . . . . . . . . . 12-112b 12-165 Cleaning . . . . . . . . . . . . . . . . . . 11-112.1b 11-156.4
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-112a 12-165 Modification . . . . . . . . . . . . . . . 11-112.1a 11-156.2
Troop/cargo winterization Turret handle:
side floor cover: Installation . . . . . . . . . . . . . . . . . . . . . 11-55b 11-76
Installation . . . . . . . . . . . . . . . . . . . . 12-114b 12-167 Removal . . . . . . . . . . . . . . . . . . . . . . . . 11-55a 11-76
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-114a 12-167 Turret lock:
Troop/cargo winterization Installation . . . . . . . . . . . . . . . . . . . . . 11-56b 11-77
top cover assembly: Removal . . . . . . . . . . . . . . . . . . . . . . . . 11-56a 11-77
Installation . . . . . . . . . . . . . . . . . . . . 12-119b 12-182
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-119a 12-180 U
top enclosure assembly: Underbody protection kit:
Installation . . . . . . . . . . . . . . . . . . . . 12-120b 12-188 Front shield installation . . . . . . . 12-186k 12-308
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-120a 12-186 Front shield removal . . . . . . . . . 12-186b 12-297
Troop/cargo winterization Front skid plate
troop seat assembly and bow: installation . . . . . . . . . . . . . . . . . . 12-186l 12-309
Installation . . . . . . . . . . . . . . . . . . . . 12-121b 12-192 Front skid plate removal . . . . . . . 12-186a 12-296
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-121a 12-190 Fuel tank shield
Troop/cargo winterization installation . . . . . . . . . . . . . . . . . . 12-186g 12.302
wheelhousing covers: Fuel tank shield removal. . . . . . . 12-186f 12-302
Installation . . . . . . . . . . . . . . . . . . . . 12-115b 12-168 Intermediate shield
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-115a 12-168 installation . . . . . . . . . . . . . . . . . . 12-186j 12-306
INDEX 32 Change 1
TM 9-2320-280-20-3
INDEX (Cont’d)
Para Page Para Page
T (Cont’d)
Intermediate shield Water can tray:
removal . . . . . . . . . . . . . . . . . . . . . 12-186c 12-298 Installation . . . . . . . . . . . . . . . . . . . . 11-108b 11-150
Rear shield installation . . . . . . . . 12-186h 12-304 Removal . . . . . . . . . . . . . . . . . . . . . . . 11-108a 11-150
Rear shield removal . . . . . . . . . . . 12-186e 12-301 Water/fuel can strap (L119):
Transfer case shield Installation . . . . . . . . . . . . . . . . . . . . 12-180b 12-273
installation . . . . . . . . . . . . . . . . . . 12-186i 12-305 Removal . . . . . . . . . . . . . . . . . . . . . . . 12-180a 12-273
Transfer case shield Weapon carrier body:
removal . . . . . . . . . . . . . . . . . . . . . 12-186d 12-300 Maintenance task summary. . . . 11-1 11-1
Weapon station backrest pad:
V Installation . . . . . . . . . . . . . . . . . . . . 11-54b 11-75
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-54a 11-75
Valve, heater shutoff
Installation . . . . . . . . . . . . . . . . . . . . 10-83b 10-137 Weapon station bumper pad:
Valve, selector: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-48a 11-69
Installation . . . . . . . . . . . . . . . . . . . . 12-9b 12-11 Weapon station hatch:
Vehicle power conditioner Removal . . . . . . . . . . . . . . . . . . . . . . . 11-42a 11-62
(VPC) mounting bracket: Weapon station hatch handle:
Vent line, air cleaner Weapon station hatch hinge:
to selector valve: Installation . . . . . . . . . . . . . . . . . . . . 11-45b 11-66
Installation . . . . . . . . . . . . . . . . . . . . 12-7b 12-9
Vent line, CDR valve: Weapon station hatch hinge pin:
Vent line, hydro-boost: Weapon station hatch
Installation . . . . . . . . . . . . . . . . . . . . 12-11b 12-14 holddown striker:
Vent line, power steering: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-46a 11-67
Installation . . . . . . . . . . . . . . . . . . . . 12-14b 12-17 Weapon station hatch latch:
Vent line, sensor cup: Removal . . . . . . . . . . . . . . . . . . . . . . . 11-50a 11-71
Installation . . . . . . . . . . . . . . . . . . . . 12-13b 12-16
Weapon station hatch tube
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-13a 12-16
Vent line, winch: assembly:
Vent, rear door: Weapon station inclinometer:
Vent stack tube, fuel tank: Weapon station tray
Installation . . . . . . . . . . . . . . . . . . . . 12-8b 12-10 and bearing seals:
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-8a 12-10 Adjustment. . . . . . . . . . . . . . . . . . . . 11-112c 11-156
Installation. . . . . . . . . . . . . . . . . . . . 11-112b 11-155
W Removal . . . . . . . . . . . . . . . . . . . . . . . 11-112a 11-154
Weapon station tray lever:
Water can bumper:
Water can/M13 decon can bumper: Weapon station tray seal:
Change 1 INDEX 33
TM 9-2320-280-20-3
INDEX (Cont'd)
Para Page Para Page
W (Cont'd)
Weapon station turret handle: Window protective shield,
Installation . . . . . . . . . . . . . . . . . . . . 11-55b 11-76 ballistic crew door:
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-55a 11-76 Initial Installation . . . . . . . . . . . . . 11-8a 11-14
Weatherstrip, windshield glass: Installation . . . . . . . . . . . . . . . . . . . . 11-8c 11-15
Installation . . . . . . . . . . . . . . . . . . . . 10-21b 10-38 Removal . . . . . . . . . . . . . . . . . . . . . . . 11-8b 11-14
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-21a 10-38 Window, soft top door:
Wheelhouse armor plate, left: Repair . . . . . . . . . . . . . . . . . . . . . . . . . 10-104 10-175
Installation . . . . . . . . . . . . . . . . . . . . 11-40b 11-60 Window stop, ballistic crew door:
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-9a 11-16
Wheelhouse armor plate, right: Windshield assembly:
Wheelhousing covers, Installation . . . . . . . . . . . . . . . . . . . . 10-23d 10-42
Installation . . . . . . . . . . . . . . . . . . . . 12-115b 12-168 Windshield ballistic glass:
Winch (6,000 lb): Removal . . . . . . . . . . . . . . . . . . . . . . . 10-22a 10-40
Installation . . . . . . . . . . . . . . . . . . . . 10-107b 10-182 Windshield glass and
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-107a 10-180 weatherstrip:
Winch (9,000 lb): Installation . . . . . . . . . . . . . . . . . . . . 10-21b 10-38
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-108a 10-184
Windshield mounting bracket:
Winch (10,500 lb), hydraulic
Installation . . . . . . . . . . . . . . . . . . . . 12-5b 12-7
and brackets:
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-5a 12-7
Brackets installation . . . . . . . . . . . . 10-108.1d10-186.4
Windshield retention bracket:
Brackets removal . . . . . . . . . . . . . . . 10-108.1c 10-186.4
Winch installation . . . . . . . . . . . . . . 10-108.1b10-186.2 Installation . . . . . . . . . . . . . . . . . . . . 10-24b 10-44
Winch removal . . . . . . . . . . . . . . . . . . 10-108.1a10-186.2 Removal . . . . . . . . . . . . . . . . . . . . . . . 10-24a 10-44
Winch (10,500 lb), hydraulic, cable: Windshield washer hoses:
Installation. . . . . . . . . . . . . . . . . . . . . . . 10-110.1b 10-190.2 Installation . . . . . . . . . . . . . . . . . . . . 10-76b 10-126
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . 10-110.1a 10-190.2 Removal . . . . . . . . . . . . . . . . . . . . . . . 10-76a 10-126
Winch (10,500 lb), hydraulic, hose: Windshield washer nozzle:
Winch: Windshield washer reservoir
Maintenance task summary. . . . 10-106 10-179 and pump assembly:
Winch cable: Installation . . . . . . . . . . . . . . . . . . . . 10-75b 10-124
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-110a 10-190 Windshield wiper arm pivot:
Winch control box: Installation . . . . . . . . . . . . . . . . . . . . 10-74b 10-123
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-109a 10-188 Windshield wiper blade and arm:
Winch vent line: Installation . . . . . . . . . . . . . . . . . . . . 10-70b 10-116
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-111a 10-192 Windshield wiper linkage:
Window, arctic: Installation . . . . . . . . . . . . . . . . . . . . 10-73b 10-122
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-75a 12-108 Windshield wiper motor
Window assembly, (SF 5578716):
ballistic crew door: Installation . . . . . . . . . . . . . . . . . . . . 10-71b 10-118
Disassembly . . . . . . . . . . . . . . . . . . . 11-7b 11-12 Windshield wiper switch/motor
Installation . . . . . . . . . . . . . . . . . . . . 11-7d 11-12 (12342501):
Removal . . . . . . . . . . . . . . . . . . . . . . . 10-72a 10-120
Index 34 Change 1
TM 9-2320-280-20-3
INDEX
Para Page
Para Page
W (Cont'd)
Wire handle lock, cargo Wiring harness, troop/cargo

shell door: winterization blackout/dome
Installation . . . . . . . . . . . . . . . . . . . . 11-14b 11-26 light:
Wiring diagrams and schematic: Removal . . . . . . . . . . . . . . . . . . . . . . . 12-105a 12-154
Appendix F . . . . . . . . . . . . . . . . . . . . F-1 Wiring harness, troop/cargo
Wiring harness (L119), trailer winterization heater:
connector and: Installation . . . . . . . . . . . . . . . . . . . . 12-101b 12-148
Removal . . . . . . . . . . . . . . . . . . . . . . . 12-163a 12-255
Wiring harness, TOW:
Installation . . . . . . . . . . . . . . . . . . . . 11-67b 11-94
Removal . . . . . . . . . . . . . . . . . . . . . . . 11-67a 11-92
Change 1 Index 35/(Index 36 blank)

TM 9-2320-280-20-3
FO-1. Electrical System Wiring Diagram.
FP-1/(FP-2 blank)
TM 9-2320-280-20-3
FO-2. Electrical System Wiring Diagram (M996 and M996A1). FP-3/(FP-4 blank)
TM 9-2320-280-20-3
FO-2. Electrical System Wiring Diagram (M996 and M996A1) (Cont’d). FP-5/(FP-6 blank)
TM 9-2320-280-20-3
FO-3. Electrical System Wiring Diagram (M997 and M997A1). FP-7/(FP-8 blank)
TM 9-2320-280-20-3
FO-3. Electrical System Wiring Diagram (M997 and M997A1) (Cont’d). FP-9/(FP-10 blank)
TM 9-2320-280-20-3
FO-4. Electrical System Wiring Diagram (M1025A2, M1035A2, M1043A2, M1045A2).
FP-11/(FP-12 blank)
TM 9-2320-280-20-3
FO-5. Electrical System Wiring Diagram (M1097A2).
FP-13/(FP-14 blank)
TM 9-2320-280-20-3
FO-6. Electrical System Wiring Diagram (M997A2).
FP-15/(FP-16 blank)
TM 9-2320-280-20-3
FO-6. Electrical System Wiring Diagram (M997A2) (Cont’d).
FP-17/(FP-18 blank)
PIN: 068171-000

TM-9-2320-280-20-3 HMMWV Unit Maintnance Vol 3

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TM-9-2320-280-20-3 HMMWV Unit Maintnance Vol 3

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ARMY TM 9-2320-280-20-3

AIR FORCE TO 36A12-1A-2092-1-3

TRUCK, UTILITY: S250 SHELTER CARRIER, 4X4, W/WINCH, M1042 (2320-01-146-7187);

Approved for public release; distribution is unlimited.

HEADQUARTERS, DEPARTMENTS OF THE ARMY,

EXHAUST GASES CAN KILL

● Loss of muscular control

5. If you see another person with exhaust poisoning symptoms:

● Do not permit physical exercise

● Administer artificial respiration, if necessary*

*For artificial respiration, refer to FM 21-11.

Dates of issue for original and

LIST OF EFFECTIVE PAGES (Cont’d)

*Zero in this column indicates original page.

TM 9-2320-280-20-3, 31 January 1996, is changed as follows:

10-37 and 10-38 10-37 and 10-38

By Order of the Secretary of the Air Force:

By Order of the Marine Corps:

CHAPTER 10 BODY AND ACCESSORIES MAINTENANCE ...................... 10-1

CHAPTER 11 SPECIAL PURPOSE BODIES MAINTENANCE ..................... 11-1

CHAPTER 12 SPECIAL PURPOSE KITS MAINTENANCE ....................... 12-1

CHAPTER 13 PREPARATION FOR STORAGE OR SHIPMENT .................... 13-1

APPENDIX A REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Section I. BODY MAINTENANCE

1 0 - 1 . BODY MAINTENANCE TASK SUMMARY

TASK PROCEDURES PAGE

1 0 - 1 . BODY MAINTENANCE TASK SUMMARY (Cont’d)

TASK PROCEDURES PAGE

10-2. FUEL FILLER HOUSING REPLACEMENT

10-3. HOOD LATCH AND BRACKET REPLACEMENT

10-3. HOOD LATCH AND BRACKET REPLACEMENT (Cont’d)

FOLLOW-ON TASK: secure hood (TM 9-2320-280-10).

10-4. HOOD PROP ROD AND BRACKET MAINTENANCE

10-4. HOOD PROP ROD AND BRACKET MAINTENANCE (Cont'd)

FOLLOW-ON TASK: Lower and secure hood (TM 9-2320-280-10).

1 0 - 5 . HOOD AND HINGE REPLACEMENT

This task covers:

1 0 - 5 . HOOD AND HINGE REPLACEMENT (Contd)

10-5. HOOD AND HINGE REPLACEMENT (Cont’d)

FOLLOW-ON TASKS: . Lower and secure hood (TM 9-2320-280-10).

10-6. OUTER HOOD SEAL REPLACEMENT

FOLLOW-ON TASK Lower and secure hood (TM 9-2320-280-10).

10-7. SIDE HOOD STOP REPLACEMENT

FOLLOW-ON TASK Lower and secure hood (TM 9-2320-280-10).

10-8. CENTER HOOD STOP REPLACEMENT

FOLLOW-ON TASK Lower and secure hood (TM 9-2320-280-10).

10-9. FOOTMAN LOOP AND STRAP REPLACEMENT

Materials/Parts Equipment Condition

FOLLOW-ON TASK Close cargo shell door (TM 9-2320-280-10).

1 0 - 9 . 1 . JACK RETAINING STRAP REPLACEMENT

1. Slide driver’s seat (1) forward.

Change 1 10-14.1/(10-14.2 blank)

10-10. CENTER HOOD STOP GUIDE REPLACEMENT

FOLLOW-ON TASK Lower and secure hood (TM 9-2320-280-10).

1 0 - 1 1 . FRONT HOOD SCREEN REPLACEMENT

This task covers:

1. Apply sealant to threads of capscrews (2).

FOLLOW-ON TASK: Lower and secure hood (TM 9-2320-280-10).

10-12. HOOD GRILLE AND SCREEN REPLACEMENT

FOLLOW-ON TASK: Lower and secure hood (TM 9-2320-280-10).

10-13. DOOR HANDLE ASSEMBLY MAINTENANCE I

This task covers:

10-13. DOOR HANDLE ASSEMBLY MAINTENANCE (Cont’d)

10-13. DOOR HANDLE ASSEMBLY MAINTENANCE (Cont’d)